Provided are a manufacturing method and a manufacturing apparatus for a seat-pad reinforcing cloth, and a molding die, with which urethane foam grows uniformly even in a thinnest wall part of a urethane seat pad, and even when a seat-pad reinforcing cloth has a complicated shape, it is not required to prepare a larger material, and deburring work is not required, thereby enabling eliminating manual work as much as possible. The manufacturing method includes: a step of putting a seat-pad reinforcing cloth material over a molding die; an upper-end-portion heat-pressing molding step of performing heat-pressing molding on an upper end portion of a seat upper ridge line portion of the seat-pad reinforcing cloth material put over the molding die, from above by an upper-end-portion heat-pressing molding device, to generate creases in a periphery of a rear part of a portion of the seat-pad reinforcing cloth material, which has been subjected to the heat-pressing molding from above; a rear-portion heat-pressing molding step of performing heat-pressing molding by a rear-portion heat-pressing molding device, together with the creases generated in the upper-end-portion heat-pressing molding step; and a front-portion heat-pressing molding step of performing heat-pressing molding by a front-portion heat-pressing molding device.
Provided are: a method and an apparatus for producing a seat-pad reinforcing cloth that enables uniform growth of urethane foam even in the thinnest part of a urethane seat pad, elimination of the need for preparing a large-size material even when the seat-pad reinforcing cloth has a complex shape, and requiring no deburring work after formation of the seat pad, thereby enabling elimination of human work as much as possible; and a molding die. The production method comprises: a step for laying a seat-pad reinforcing cloth material over a molding die; a top-end hot press molding step for subjecting a top-end of an upper seat-ridge portion of the seat-pad reinforcing cloth laid over the molding die to hot press molding from above by a top-end hot press-molding device and forming wrinkles on the periphery of a posterior portion of the area subjected to the hot press molding; a posterior-portion hot press molding step for subjecting all of the wrinkles formed by the top-end hot press molding step to hot press molding by a posterior-portion hot press molding device; and an anterior-portion hot press molding step for performing hot press molding by an anterior-portion hot press molding device.
B60N 2/90 - Details or parts not otherwise provided for
A47C 27/15 - Spring, stuffed or fluid mattresses specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
3.
Fabric-like material for reinforcement in urethane foam molding, and method for producing urethane foam molded body utilizing same
B29C 44/12 - Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
B29C 33/16 - Moulds or coresDetails thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels against the mould wall using magnetic means
D06M 11/83 - Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with metalsTreating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with metal-generating compounds, e.g. metal carbonylsReduction of metal compounds on textiles
D06M 13/02 - Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials with non-macromolecular organic compoundsSuch treatment combined with mechanical treatment with hydrocarbons
D06M 15/227 - Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated
D06M 15/333 - Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof of vinyl acetatePolyvinylalcohol
B29C 70/88 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
B29C 44/00 - Shaping by internal pressure generated in the material, e.g. swelling or foaming
B29K 75/00 - Use of polyureas or polyurethanes as moulding material
B29C 39/10 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
D06M 23/08 - Processes in which the treating agent is applied in powder or granular form
C08J 5/04 - Reinforcing macromolecular compounds with loose or coherent fibrous material
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
4.
FABRIC-LIKE MATERIAL FOR REINFORCEMENT IN URETHANE FOAM MOLDING, AND METHOD FOR PRODUCING URETHANE FOAM MOLDED BODY UTILIZING SAME
This fabric-like material (1) for reinforcement in urethane foam molding is obtained by impregnating a part of the surface of an nonwoven fabric (2) of organic fibers with a hot melt magnetic material (3) and immobilizing the hot melt magnetic material (3). This fabric-like material (1) for reinforcement in urethane foam molding is characterized in that the hot melt magnetic material (3) satisfies the composition described below, while having a softening point of from 70°C to 100°C (inclusive). An ethylene-vinyl acetate copolymer (A): from 10% by mass to 95% by mass (inclusive) A wax (B): from 0% by mass to 30% by mass (inclusive) A magnetic powder (C): from 5% by mass to 70% by mass (inclusive) (In this regard, the total of the components (A), (B) and (C) is taken as 100% by mass.)
D06M 11/83 - Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with metalsTreating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with metal-generating compounds, e.g. metal carbonylsReduction of metal compounds on textiles
B29C 33/16 - Moulds or coresDetails thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels against the mould wall using magnetic means
B29C 39/10 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
B29C 44/00 - Shaping by internal pressure generated in the material, e.g. swelling or foaming
B29C 70/88 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
C08J 5/04 - Reinforcing macromolecular compounds with loose or coherent fibrous material
D06M 13/02 - Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials with non-macromolecular organic compoundsSuch treatment combined with mechanical treatment with hydrocarbons
D06M 15/227 - Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated
D06M 15/333 - Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof of vinyl acetatePolyvinylalcohol
D06M 23/08 - Processes in which the treating agent is applied in powder or granular form
B29K 105/06 - Condition, form or state of moulded material containing reinforcements, fillers or inserts
5.
Reinforcing base fabric for urethane-foamed product
B32B 27/06 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
B32B 5/22 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
Embodiments of the present invention may include a vehicle seat having a cushion pad, a surface member, and a rigid member. The cushion pad may be equipped with a main portion for supporting an occupant, and a side support portion provided on a side of the main portion. The side support portion may protrude from the main portion so as to support the occupant. The surface member is provided on a surface of the cushion pad. The rigid member is provided inside the side support portion of the cushion pad. The rigid member is of higher rigidity than the cushion pad, and protrudes in the same direction in which the side support portion protrudes. The rigid member has an end portion contacting the surface member.
An apparatus for manufacturing a reinforcing cloth of a seat pad which includes: a mold for fixing a sheet and having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface; a closed space between the mold and a cover member formed by covering the sheet fixed on the mold with the cover member; a heating unit for heating the sheet; and an exhausting unit for exhausting air from the closed space is provided.
D04H 1/00 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
B29C 35/04 - Heating or curing, e.g. crosslinking or vulcanising using liquids, gas or steam
B29C 51/10 - Forming by pressure difference, e.g. vacuum
B29C 51/28 - Component parts, details or accessoriesAuxiliary operations for applying pressure through the wall of an inflated bag or diaphragm
B29C 43/36 - Moulds for making articles of definite length, i.e. discrete articles
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
A method for producing a casting die by simple work without requiring high work skill in which the work days required for producing the casting die can be shortened greatly. A die model employed suitably in this production method, an NC processing system and a processing robot are also provided. The method for producing the casting die comprises; (1) a die data making step for designing a required die in accordance with the profile of a product and making the die data, (2) an automatic processing preparation step for making the machining data of an automatic processing machine based on the die data, (3) a die model cutting step for making a die model by cutting a die model material with the automatic processing machine, (4) a die mold making step for making a mold for a die by packing a case with casting sand to provide a gate and hardening the casting sand with bond, (5) a die casting step for casting the die, and (6) a finishing assembly step for finishing and assembling the die.
A method of manufacturing a reinforcing cloth of a seat pad includes: fixing a sheet on a mold having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface; forming a closed space between the mold and a cover member by covering the sheet fixed on the mold with the cover member; heating the sheet; shaping the heated sheet into a shape following the outer shape of the mold by exhausting air from the closed space through the air holes; and demolding the sheet from the mold after removing the cover member.
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