Honda Giken Kogyo Kabushiki Kaisha

Tetsuo Kita

Masahiro Miyazaki

Tsutomu Saka

Minoru Maeda

An improved process for producing a laminated resin foam composed of two resin foam layers of different characteristic properties wherein the layers are integrally bonded together. A first foamable resin liquid for forming flexible foam is poured into a first space in a foam processing mold on one side of a barrier projecting from the wall of the mold and pouring a second foamable resin liquid for forming a foam less flexible than the first flexible foam into a second space in said foam processing mold on the other side of said barrier. The two foamable resin liquids foam beyond the barrier into contact with each other to form the two laminated foam layers. One improvement in the process includes wetting a substantial portion of the mold cavity with the first foamable resin liquid. Various shapes of molds and barriers will produce different shapes and characteristics of the resultant foam pad, such as for a car seat.

Process for producing laminated resin foam

A fabric web having a high modulus of elasticity is used as a spring element in an upholstered article such as a seat or a bed. The fabric web is joined to a metal rod serving as a frame member of the upholstered article by an end portion of the fabric web, which is folded on itself over the metal rod to provided folded and unfolded layers that are united together by means of a heat-fusible resin film. The heat-fusible resin film is held against the inner surface of the folded end portion of the fabric web and fused by high-frequency welding. The folded end portion of the fabric web is protected by the intermediary film against damage which would otherwise be caused by abrasive contact with a rust layer on the metal rod. The film sandwiched between the folded and unfolded layers has opposite ends folded and fused over the unfolded layer of the fabric web for reinforcing marginal edges of the fabric web. The film is stretched for molecular reorientation to provide increased mechanical strength in the direction in which the fabric web is tensioned during use of the upholstered article.

Growing community of inventors

Saitama, Japan

Tetsuo Kita