MOLD FOR FOAM MOLDING AND METHOD FOR PRODUCING FOAM-MOLDED MEMBER

• US 20120286445A1
• Filed: 01/27/2011
• Published: 11/15/2012
• Est. Priority Date: 01/28/2010
• Status: Active Grant

• Current Assignee: Archem, Inc.
• Original Assignee: Bridgestone Corporation
• Inventors: Ohta, Masato
• Granted Patent: US 9,403,292 B2
• Time in Patent Office: Days
• US Class Current: 264/46.4
• CPC Class Codes: B29C 33/14 against the mould wall
• CPC Class Codes: B29C 33/16 using magnetic means
• CPC Class Codes: B29C 44/1228 Joining preformed parts by the expanding material
• CPC Class Codes: B29C 44/1233 the preformed parts being supported during expanding
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 44/351 Means for preventing foam to leak out from the foaming device during foaming
• CPC Class Codes: B29C 44/58 Moulds
• CPC Class Codes: B29K 2105/0809 Fabrics
• CPC Class Codes: B29K 2623/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2623/12 PP, i.e. polypropylene
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751

Abstract

Disclosed is a mold for foam molding capable of making the operation to attach a reinforcing member to an inner surface of a mold easier, capable of sufficiently preventing entry of foam synthetic resin between the reinforcing member and the inner surface of the mold at the time of foam-molding, and capable of preventing the reinforcing member from becoming wrinkled; and also provided is a method for producing a foam-molded member which has a reinforcing member using this mold for foam molding. A mold 20 for foam molding is used to foam-mold a seat pad 1 which is provided with a seat pad main body 2 and a reinforcing member 10 disposed on the back side of the seat pad main body 2. At the time of foam-molding, the reinforcing member 10 is disposed inside the mold 20 and an end edge of the reinforcing member 10 is secured to the inner surface of the mold 20 by a securing means. A tension application means is provided which applies tension to the end edge of the reinforcing member 10 in a direction to separate from the securing means.

Claims

1. A mold for foam molding adopted for foam-molding a foam-molded member which is provided with a foam-molded body and a sheet-shaped reinforcing member disposed along at least a part of a surface of the foam-molded body,

the reinforcing member being to be disposed in the mold such that at least a part of an end edge of the reinforcing member is secured to the inner surface of the mold by a securing means,

wherein the mold comprises a tension application means for applying tension to the end edge of the reinforcing member in a direction separating from the securing means in a state in which the end edge of the reinforcing member is secured to the inner surface of the mold.

2. The mold for foam molding according to claim 1, wherein:

the reinforcing member includes an opening;

the end edge is a peripheral edge portion of the opening;

the peripheral edge portion of the opening is at least partially secured to the inner surface of the mold by the securing means; and

the tension is applied to the peripheral edge portion by the tension application means in a direction to separate from the securing means and the opening.

3. The mold for foam molding according to claim 1, wherein the plural securing means are provided at intervals along a direction in which the end edge of the reinforcing member extends.

4. The mold for foam molding according to claim 1, wherein the reinforcing member is disposed with at least a part of the end edge thereof facing downward on the inner surface of the mold.

5. The mold for foam molding according to claim 1, wherein the securing means includes a magnet provided in one of the reinforcing member and the inner surface of the mold, and a magnetic body provided in the other, the magnetic body being capable of being attracted and held by the magnet.

6. The mold for foam molding according to claim 1, wherein the tension application means is constituted by a projecting portion which projects from the inner surface of the mold so that a portion of the reinforcing member further distanced from the end edge of the reinforcing member than the securing means is separated from the inner surface of the mold.

7. The mold for foam molding according to claim 6, wherein a projection height T of the projecting portion from the inner surface of the mold is 3 to 15 mm.

8. The mold for foam molding according to claim 6, wherein a distance D₁ between the projecting portion and the securing means is 50 mm or less.

9. The mold for foam molding according to claim 6, wherein a tip portion of the projecting portion is shaped such that a width W thereof along a direction close to and away from the securing means is reduced toward the tip of the projecting portion.

10. The mold for foam molding according to claim 6, further comprising a securing means for securing at least a part of the reinforcing member to the inner surface of the mold, wherein said part is further distanced from the end edge of the reinforcing member than the projecting portion.

11. A method for producing a foam-molded member which is provided with a foam-molded body and a sheet-shaped reinforcing member disposed along at least a part of a surface of the foam-molded body,

said method using the mold for foam molding according to claim 1, and comprising:

a reinforcing member disposing process to dispose the reinforcing member to the inner surface of the mold and to secure an end edge of the reinforcing member to the inner surface of the mold by the securing means; and

a foam-molding process to foam-mold the foam-molded body inside the mold,

wherein the tension is applied to the end edge of the reinforcing member in a direction to separate from the securing means by the tension application means in a state in which the end edge of the reinforcing member is secured to the inner surface of the mold.

12. The method for producing a foam-molded member according to claim 11, wherein at least the end edge of the reinforcing member is made of nonwoven fabric.

13. The method for producing a foam-molded member according to claim 11, wherein the foam-molded member is a seat pad.

14. The method for producing a foam-molded member according to claim 13, wherein:

the seat pad has an airbag device housing room for housing an airbag device, and a to-be-ruptured portion which ruptures when the airbag is inflated on a wall surface of the airbag device housing room;

the reinforcing member is disposed at least partially along the wall surface of the airbag device housing room;

the reinforcing member includes an opening which is placed over the to-be-ruptured portion; and

in the reinforcing member disposing process, a peripheral edge portion of the opening is at least partially secured to the inner surface of the mold by the securing means, and the tension is applied to the peripheral edge portion by the tension application means in a direction to separate from the securing means and the opening.

15. The method for producing a foam-molded member according to claim 14, wherein the opening is formed in a groove shape and a longitudinal edge portion of the opening is at least partially secured to the inner surface of the mold by the securing means.