Mold for foam molding and method for producing foam-molded member

• US 9,403,292 B2
• Filed: 01/27/2011
• Issued: 08/02/2016
• Est. Priority Date: 01/28/2010
• Status: Active Grant

• Current Assignee: Archem, Inc. (Bridgestone Corporation)
• Original Assignee: Bridgestone Corporation
• Inventors: Ohta, Masato
• Primary Examiner(s): Malekzadeh, Seyed Masoud
• Application Number:
  US13/574,130
• Publication Number:
  US 20120286445A1
• Time in Patent Office: 2,014 Days
• Field of Search: 425/3, 425/4.R, 425/111, 425/121, 425/123, 425/817.R
• US Class Current: 1/1
• 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,

wherein the reinforcing member comprises an opening that is a through hole at a surface of the reinforcing member;

the mold comprises a projecting portion, securing members disposed around the projecting portion, and a tension application member; and

at least one of the securing members is disposed closer to the projecting portion than the tension application member is; and

wherein

in a state in which the reinforcing member is secured to an inner surface of the mold,

the projecting portion is inserted through the opening of the reinforcing member;

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

tension is applied to the peripheral edge portion by the tension application member in a direction so as to urge separation from the securing members and the opening, thereby tensioning the peripheral edge portion of the opening.

2. The mold for foam molding according to claim 1, further the securing members are provided at intervals along a direction in which an end edge of the reinforcing member extends.

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

4. The mold for foam molding according to claim 1, wherein the securing members comprises 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.

5. The mold for foam molding according to claim 1, wherein the tension application member comprises a projection which projects from the inner surface of the mold so that a portion of the reinforcing member further distanced from an end edge of the reinforcing member than the at least one of the securing members is separated from the inner surface of the mold.

6. The mold for foam molding according to claim 5, wherein a projection height T of the projection from the inner surface of the mold is 3 to 15 mm.

7. The mold for foam molding according to claim 5, wherein a distance D₁ between the projection and the at least one of the securing members is 50 mm or less.

8. The mold for foam molding according to claim 5, wherein a tip portion of the projection is shaped such that a width W thereof along a direction close to and away from the at least one of the securing members is reduced toward a tip of the projection.

9. The mold for foam molding according to claim 5, further the securing members configured to secure 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 projection.