Ikeda Bussan Co. Ltd.

Norio Yanagishita

Ichiro Matsuura

Masami Mori

Kiichiro Ishimaru

Masanobu Kikuchi

Koji Yamada

Hisayoshi Mizuno

Youichi Omata

Takashi Sugiura

Mikio Akai

Yoichi Omata

A method of integrally bonding a foam seat pad or other article to a cover material includes steps of positioning a two ply cover material in a set stand of a lower mold. The set stand positions a main surface portion of the cover material in a desired alignment while a retaining member is used for provisionally maintaining the alignment. Side mold portions are moved in position to firmly surround the set stand and and the retaining member is removed. Then, foam resin is introduced into the space defined by the set stand and side mold portions and an upper mold is used to sealingly cover the molding apparatus. After the upper mold is closed pressurization of the internal space of the molding apparatus is effected for a desired time during setting of the foam resin.

Method and apparatus for integrally attaching a cover material to a

A method of integrally bonding a foam seat pad or other article to a cover material, includes steps of coating a main surface of the pad with a heat activated adhesive. Then, the pad is affixed to an upper mounting member. A lower mounting member is positioned opposite the upper mounting member and the cover material is disposed on the lower mounting member. Heating is applied to the adhesive coating the main surface of the pad, and when sufficient heat is applied the upper and lower mounting members are pressed together for a predetermined time period. Clamps are provided on the mounting members for surely positioning the pad relative the cover material. Thus, accurate positioning and strong bonding are reliably assured.

Method of manufacturing article including integrated cover material

A position adjustable headrest includes a bag-shaped outer skin member defining an inside space thereof. The outer skin member has first inwardly-bent end portions which are opposed to and in abutment with each other. The first inwardly-bent end portions define a first slit therebetween. The outer skin member has second and third slits formed therethrough which are opposed to each other and extend from longitudinally opposed ends of the first slit. A pad member made of plastic is covered by the outer skin member. The plastic is foamed and cured in the inside space so as to fill the inside space with the plastic and to press the first inwardly-bent end portions against each other, thereby closing the first slit tightly to prevent the plastic from leaking out through the first slit. Two stays project outwardly through the second and third slits respectively.

Position adjustable headrest

A method of molding a skin-covered foamed article includes the steps of (a) putting an outer skin member having an opening to a mold; (b) putting a frame in the outer skin member; (c) setting a pair of wires at the end portion of the outer skin member so that the opening is tightly closed; (d) pouring a liquid foamable material in the outer skin member upon opening the opening; (e) closing the opening and the mold and curing the liquid foamable material; and (f) removing the wires from the outer skin member.

Method of molding skin-covered foamed article

A method of manufacturing a skin cover capable of making desired curved portions on the skin cover without deforming or damaging the skin cover and without creating wrinkles on the skin cover. The method includes the steps of placing one of the surface skin and the wadding along a manufacturing surface having a shape corresponding to the curved sections such that the one of the surface skin and the wadding is kept in a desired curved shape; and attaching another one of the surface skin and the wadding to the one placed along the manufacturing surface to obtain the skin cover in the desired curved shape.

Method of manufacturing skin cover for seat

A method of molding a skin-covered foamed article is disclose. The method includes the steps of (a) preparing a mold assembly has a lower mold which has a cavity formed therein and an upper mold which is adapted to be put on the lower mold to close the cavity, the lower mold including a fixed mold part which has around the bottom of the cavity a seat portion and a movable mold part which has a peripheral portion which is adapted to be seated on the seat portion; (b) preparing a bag-shaped outer skin member; (c) lining one surface of the bag-shaped outer skin member with a film to provide a film-lined bag-shaped outer skin member; (d) putting the film-lined bag-shaped outer skin member on the movable mold part in such a manner that the film constitutes an outermost layer of the outer skin member on the movable mold part and that at least the peripheral portion of the movable mold part is covered with the film; (e) moving the movable mold part to its operative position having the peripheral portion of the movable mold part intimately seated on the seat portion of the fixed mold with an interposal of the film therebetween; (f) pouring a liquid foamable material for foamed plastic into the cavity; and (g) putting the upper mold onto the lower mold to close the cavity and curing the foamable material.

A mold for molding a skin covered foamed plastic article capable of dealing with those foamed plastic articles having large curving portions without complicating the manufacturing process relating to the attachment of the skin member on the mold, without a leakage of liquid formed plastic to be poured over the mold. The mold includes a lower mold, over which a skin cover is to be placed, and on which liquid foamed plastic is to be poured onto the skin cover, the lower mold having; a fixed part on top of which the upper mold is to be placed; a movable part which makes contact with the fixed part at a lowered position at which there is a closed space between the fixed part and the movable part; and means for controlling air pressure inside the closed space between the fixed part and the movable part. A method of manufacturing a skin covered foamed plastic article using this mold is also disclosed.

Mold for skin covered foamed plastic molding

A mold for skin covered foamed plastic molding which utilizes a middle mold to be placed between an upper mold and a lower mold, capable of reducing the weight of the middle mold so that assembling of the middle mold becomes less troublesome, the assemblage becomes more stable and the appearance of undesirable spacing in the assemblage an be prevented. The mold includes an upper mold to be closed over the lower mold, having a bent portion with a bottom surface which is to be a part of molding surface; and a middle mold to be placed between the upper mold and the lower mold, having a hollow region into which the bent portion of the upper mold is to be engaged when assembled.

A mold for skin covered foamed plastic molding which utilizes a middle mold to be placed between an upper mold and a lower mold, capable of avoiding an excessive amount of pressure to be exerted on the upper portion of the lower mold so that the durability of the lower mold can be improved, and preventing gaseous leakage so that the penetration of the liquid foam resin to be poured on a skin cover becomes controllable. The mold includes an upper mold to be closed over the lower mold, having extended side portions which can reach the base of the lower mold when assembled such that the extended side portions can support the upper mold by themselves.

A mold for manufacturing a skin covered foamed plastic seat capable of structually preventing the leakage of the liquid foam resin from a space between the skin cover and the bossings provided on the mold for the holes to be made on it. The mold includes a lower mold over which a sink cover is to be placed, having a protruded portion to be inserted into a hole on the skin cover corresponding to a hole to be made on the skin covered foamed plastic seat, the protruded portion having a circumference smaller than that of the hole on the skin cover, and the upper mold to be assembled with the lower mold, having a bossing for making the hole to be made on the skin covered foamed plastic seat, the bossing having a concavity to be engaged with the protruded portion of the lower mold at a bottom, and a circumference larger than that of the hole on the skin cover.

Mold for manufacturing skin covered foamed plastic seat with holes

A method of producing a frame-installed seat pad structure, which includes by steps (a) preparing a mold assembly which includes a mold and a lid, the lid having a foamable material feeding tube connected thereto; (b) preparing an endless elongate member which defines therein and therealong a continuous way, the endless elongate member having an inlet portion matable with the feeding tube of the lid and a plulality of outlet portions; (c) detachably connecting the endless elongate member to the lid having the inlet portion thereof mated with material feeding tube; (d) putting the lid on the mold having the endless elongate member exposed to a cavity of the mold; (e) pouring a foamable plastic material into the material feeding tube, so that the material flows in and along the continuous way and falls into the cavity through the outlet portions; (f) curing the material; and (g) removing the lid from the mold when the material is hardened to a certain degree.

Method of producing frame-installed seat pad structure

A skin covered foamed plastic seat capable of structurally preventing the appearance of creases due to the parting lines of the mold. The skin covered foamed plastic seat includes a skin cover including a surface skin to form an outer surface of the skin covered foamed plastic seat and a wadding to be laminated with the surface skin, the skin cover having end sections to be pinched in parting line portions of a mold for manufacturing the skin covered foamed plastic seat, at which the lamination of the wadding over the surface skin is weaker than that in remaining sections of the skin cover.

Skin covered formed plastic seat

A skin covered foamed plastic article capable of providing improved softness, feel and comfortableness by reducing the amount of penetration of the liquid foam resin into the skin cover with a thin wadding. The article includes a wadding to be attached on a back side of the surface skin and to make a direct contact with the pad member, having a soft layer contacting the surface skin and a hard layer contacting the pad member which has a constant thickness and is made to be harder than both the soft layer and the pad member.

Skin covered foamed plastic article

Herein disclosed is a mold assembly for molding a frame-installed and skin-covered seat cushion structure, which includes a mold having a cavity formed therein; a retainer jig adapted to be put on the mold, the retainer jig being equipped with clamps for clamping a frame of the seat cushion structure to be produced; a lid adapted to be put on the mold with an interposal of the retainer jig therebetween; and a sealing element for achieving a sealing between the mold and the lid upon proper putting of the lid on the mold.

Mold assembly for molding frame-installed and skin-covered seat cushion

A method of producing a skin-covered foamed plastic article, which includes preparing a lower mold which has a cavity formed therein; putting a bag-shaped outer skin member into the cavity, the skin member having a porous inner layer; pouring a foamable material for the foamed plastic article into the bag-shaped outer skin member; and adjusting a pressure which is created in the cavity due to foaming of the foamable material.

Growing community of inventors

Ayase, Japan

Norio Yanagishita