JP2000116469A - Cushion body and is production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent part of the woven fabric of a cushion body from being excessively tensed and slackened by load impartation. SOLUTION: This cushion body 2 is constituted by integrally and successively providing an outer peripheral frame part 5 made of a synthetic resin with the outer peripheral end of the woven fabric 6 having flexibility and elasticity. The part nearer the bore than the outer peripheral frame part 5 is provided with reinforcing bodies 7 consisting of a pair of rib parts 7a and 7b integrally connected to the woven fabric 6 and thin successive provision parts 7b between both rig parts 7a and 7a. The thin successive provision parts 7b of the reinforcing bodies 7 are cut off together with the woven fabric 6 so that the free ends are formed. Then, the woven fabric 6 is interrupted by the disconnected thin successive provision parts 7b and, therefore, the excessive tensing and slackening by the load impartation do not occur and the surface of the woven fabric 6 is easily made to comply with a three-dimensional curvilinear surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion body for a chair seat or the like and a method for manufacturing the cushion body.

[0002]

2. Description of the Related Art Conventionally, Japanese Patent Publication No. Hei 7-38817 discloses a seat plate for a chair integrally formed of a synthetic resin material as an invention in which the sitting comfort of the seat body is improved. Inward from the left and right side edges, a pair of left and right thin vertical flexible wire portions extending in the front-rear direction, and a thin horizontal flexible wire portion continuously connected between the pair of vertical flexible wire portion front ends; A configuration in which an outer edge of a vertical flexible wire portion has an outward flexible protrusion is disclosed.

However, in this configuration, the seat plate is easily bent around the left and right axes around the horizontal flexible line portion, but there is a problem that the seat plate is difficult to bend in the front-rear direction.
On the other hand, as a seat in a chair or the like, for example,
As disclosed in Japanese Patent No. 83062, as a method of stretching a net-like or the like woven fabric on the inner diameter portion of a frame having a three-dimensional curved surface made of a synthetic resin, a pair of upper and lower molds for injection molding is used. Forming a cavity corresponding to the frame body, standing a plurality of pins in the cavity of the lower mold, and aligning the upper and lower molds in a state where the ends of the woven fabric are locked to these pins, It has been proposed to inject a molten resin into the cavity and mold it.

[0004]

However, in the seat body thus formed, a net-like woven cloth stretched in a plane on the inner diameter of the frame body having the three-dimensional curved surface is partially formed. There is a problem that it is not possible to impart uniform tension to the woven fabric, such as loosening, or only a part of the woven fabric is over-tensioned. If the surface is curved along the curved surface of the person's buttocks or underside of the thighs, the vertical and horizontal strands (warp and weft) tensions will be partially different. There is a problem that the convex curvature is not deepened, the feeling of pressure becomes large, and the sitting comfort is deteriorated.

An object of the present invention is to solve these problems, and an object of the present invention is to provide a cushion body such as a seat body having a comfortable sitting (rest) comfort.

[0006]

According to a first aspect of the present invention, there is provided a cushion body according to the first aspect of the present invention, wherein an end portion of a woven cloth having flexibility or elasticity is formed with an outer peripheral frame portion made of synthetic resin. A cushion body integrally connected, wherein a pair of rib portions integrally connected to the woven fabric and a thin continuous portion between the two rib portions are provided on an inner diameter portion from the outer peripheral frame portion. The reinforcing member is provided, and the thin continuous portion of the reinforcing member is cut off together with the woven fabric to form a free edge.

According to a second aspect of the present invention, there is provided a cushion body manufacturing method, comprising: a first cavity corresponding to an outer peripheral frame portion of the cushion body; A pair of upper and lower molds having a second cavity corresponding to a thin continuous portion between the two rib portions and facing the end of a flexible or elastic woven fabric in the first cavity, After being arranged in the second cavity so as to pass through the middle part of the woven fabric, a molten synthetic resin material is injected into both cavities and solidified, and between the two rib portions in the cushion body extracted from both dies. The thin continuous portion is cut off.

[0008]

Next, embodiments of the present invention will be described. FIG. 1 is a perspective view of a chair 1 having a cushion body 2 of the present invention as a seat, and FIG. 2 is an explanatory view showing a method of manufacturing the cushion body 2 of the present invention. The cushion body 2 of the present invention can be used as a seat attached to the legs 3 and 3 made of a metal pipe having a U-shaped downward facing side view on both left and right sides, and can be used for the backrest 4. .

The cushion body 2 has an outer peripheral frame portion 5 made of a synthetic resin material and a flexible or elastic woven fabric made of a synthetic resin fiber or the like having an outer peripheral end integrally connected to the outer peripheral frame portion 5. The woven fabric 6 is composed of a cloth 6 and a reinforcing member 7 made of a synthetic resin material and located at an inner diameter portion of the outer peripheral frame portion 5 and integrally connected to the woven fabric 6. In the first embodiment, as shown in FIGS. 1 and 3, the reinforcing member 7 is formed in a substantially U-shape in plan view, and includes a pair of thick-walled rib portions 7a, 7a and And a thin continuous portion 7b between the ribs 7a.

As will be described later, the outer peripheral frame portion 5 and the reinforcing member 7 are integrally formed via a woven fabric 6 sandwiched between upper and lower molds 11 and 12 for injection molding in advance. And highly rigid engineering plastics such as saturated polyester resin, polyamide resin (nylon 66
Etc.), polyacetal, polycarbonate (PC), modified polyphenylene ether (PPE), polyphenylene sulfide (PPS), thermoplastic polyester resin (P
BT, PCT, PBN, PET, etc.), and glass reinforced plastics mixed with short glass fibers.

The woven fabric 6 is made of a polyamide resin (nylon 6
6), polyethylene (PE), polypropylene (P
P), polyvinyl alcohol (EVA), polyvinylidene chloride (PVDC), thermoplastic elastomer (TPE)
The one woven using warp and weft of synthetic fibers such as In the first embodiment, the warp yarns and the weft yarns in the woven fabric 6 are filaments (single fibers) or yarns (twisted yarns) and have flexibility or high rubber elasticity (high stretch ratio). There may be. These warp yarns and weft yarns are arranged orthogonally and parallel to the extending direction of the U-shaped rib portion 7a in the reinforcing body 7 in plan view.

After the injection molding, the thin continuous portion 7b of the reinforcing body 7 is cut by a cutter or the like, and at least the warp and the weft of the woven fabric 6 passing through the thin continuous portion 7b are also cut. It is configured so that a free edge is formed on the body 7. 2 (a), 2 (b) and 2
(C) shows the method for manufacturing the cushion body 2 of the present invention.
The upper and lower molds 11 and 12 have a first cavity 13 having a substantially rectangular frame shape or the like (annular shape) corresponding to the outer peripheral frame portion 5 of the cushion body 2, and an inner diameter from the outer peripheral frame portion 5, that is, the first cavity 13. Position, the pair of rib portions 7a,
A second cavity 14 corresponding to 7a and a thin continuous portion 7b between the ribs 7a, 7a is formed.

The outer peripheral edge of the flexible (elastic) woven fabric 6 disposed between the pair of upper and lower molds 11 and 12 faces the first cavity 13, and the second cavity 14. Is arranged so as to pass through the middle part of the woven fabric 6 (see FIG. 2A). In this case, in order to prevent the middle part of the woven fabric 6 from being loosened, the outer peripheral edge of the woven fabric 6 is appropriately tensioned by the clamper 15. After that, the above-mentioned molten synthetic resin material is injected into both cavities 13 and 14 from the gate 16 by combining the upper and lower molds 11 and 12 (FIG. 2).
(Refer to (b)) An injection molding method of solidifying is adopted.
The thin continuous portion 7b between the ribs 7a, 7a in the cushion body 2 extracted from the upper and lower molds 11, 12 is
It is separated by the cutter 17 (see FIG. 2C). In addition, the end of the woven fabric 6 protruding from the outer peripheral edge of the outer peripheral frame 5 is cut off by the cutter 17 to adjust the appearance.

The cushion body 2 manufactured by the above-described method (not shown, a bracket for attaching to the leg 3 is integrally formed on the lower surface of the outer peripheral frame 5).
When the person M sits on the chair 1 with the legs fixed to the legs 3, as shown in FIG. 4, the load on the buttocks H of the person M is applied to the vicinity of the reinforcing portion 7 in the cushion body 2, and the thigh L of the person M Is applied from the reinforcing portion 7 to the forward portion. And
The base 7 of the pair of ribs 7a, 7a in the reinforcing portion 7
Because of the load, the downward bending amount of the rib portion 7a located on the center side is smaller than the downward bending amount of the rib portion 7a on the side close to the outer peripheral frame portion 5 because the ribs 7a are separated except for the portions c and 7c. Cushion body 2 which can be continuously increased
The elastically bent curved surface of the portion of the woven fabric 6 is exactly matched with the shapes of the lower surfaces of the buttocks H and the thighs L of the sitting person M,
It is possible to provide a comfortable cushion body. When a three-dimensional bending curve of the woven fabric 6 occurs due to a downward load on the woven fabric 6 at the inner diameter portion of the outer peripheral frame portion 5, a pair of rib portions 7 a, 7 a of the reinforcing body 7 are provided.
Since the free end of the woven fabric 6 is fixed at the position (1), there is an effect that no fraying occurs, and it is easy to form a bent curved surface that can fit the shape of the load side well.

The thin continuous portion 7b at the bases 7c and 7c is easily cut by the shearing force at the end where the thin continuous portion 7b is cut off by the cutter 17, so that a crack is easily formed.
It is preferably formed in a circular thin continuous portion 7b '. 5 (a), 5 (b) and 5 (c) show a second embodiment of a method of manufacturing the cushion body 2, wherein the outer peripheral frame 5 is made of a metal or the like and has a substantially rectangular frame shape (in plan view). An engineering plastic similar to that of the first embodiment may be fitted on the outer periphery of the (circular) core material 19. In this case, the outer peripheral edge of the woven fabric 6 is wound around the core material 19 in advance and bonded. The core material 19 and the woven fabric 6 are fixed to the upper and lower molds 1.
When arranged between the first and second cores 12, the core member 19 is inserted into the first cavity 13 (see FIG. 5A). The core material 19
A plurality of restricting pins 20 may be protruded from the outer periphery of the core material 19 at a plurality of locations so that the winding end of the woven fabric 5 is located at a substantially central position in the cross section of the first cavity 13. 1
Predetermined positioning means may be formed in 1 and 12. A predetermined type of molten synthetic resin material is injected from the gate 16 and solidified (see FIG. 5B). Upper and lower molds 11,
Separating the thin continuous portion 7b between the ribs 7a, 7a of the cushion body 2 extracted from 12 with a cutter 17 is the same as in the first embodiment (see FIG. 5C).

FIG. 6 includes a pair of ribs formed on the inner diameter of the outer peripheral frame 5 and a thin continuous portion between the ribs.
The embodiment of the cushion body 2 in which the reinforcing body 21 formed by separating the thin continuous portion 21b is substantially linear in plan view is shown.
FIG. 7 shows two reinforcing members 22 and 23 (which have a pair of rib portions and a thin continuous portion between the rib portions as in the first embodiment,
The cushion body 2 in which the thin continuous portions 22b and 23b are separated from each other is formed on the inner diameter portion of the outer peripheral frame portion 5. In the embodiment shown in FIGS. 6 and 7, the warp yarns and the weft yarns of the woven fabric 6 are arranged so as to extend non-parallel and non-perpendicularly to the extending direction of the ribs of the reinforcing members 21, 22, 23. Also in the first embodiment, the warp and the weft may be arranged to extend in the same direction. Further, the warp and the weft in the woven fabric 6 may be arranged to extend obliquely to each side of the outer peripheral frame portion 5 having a substantially rectangular shape in a plan view.

It goes without saying that the cushion body of the present invention can be applied to a portion corresponding to a backrest portion of a chair.

[0018]

As described in detail above, in the cushion body according to the first aspect of the present invention, the end of the flexible or elastic woven fabric is integrally formed with the outer peripheral frame made of synthetic resin. A cushion body which is continuously provided, wherein a reinforcing member comprising a pair of rib portions integrally connected to the woven fabric and a thin continuous portion between the both rib portions on an inner diameter portion from the outer peripheral frame portion. And the thin continuous portion of the reinforcing member is cut off together with the woven fabric to form a free edge.

According to the cushion body having this configuration, when a load in a direction crossing the surface of the woven fabric is applied to the woven fabric portion at the inner diameter portion from the outer peripheral frame portion, the surface of the woven fabric is three-dimensionally curved. However, since the thin continuous portion between the pair of rib portions of the reinforcing member disposed closer to the inner diameter portion than the outer peripheral frame portion is cut off, a three-dimensional curved surface is not formed at the cut-off portion. Being continuous, the woven fabric can flex to closely follow the surface of the loaded side.

In other words, since the woven fabric is cut at the cut-off point in the reinforcing member, when the surface of the woven fabric is bent on the three-dimensional curved surface by the load on which the object is placed, the conventional structure is used. As described above, the phenomenon that a part of the woven fabric having the outer peripheral edge fixed to the outer peripheral frame in a ring shape is not excessively tensioned or loosened. Therefore, it is possible to provide a cushion body that is comfortable to sit on without unnecessarily and non-uniformly pressing a soft part pressing the surface of the cushion body.

According to a second aspect of the present invention, there is provided a cushion body manufacturing method, comprising: a first cavity corresponding to an outer peripheral frame portion of the cushion body; A pair of upper and lower molds having a second cavity corresponding to a thin continuous portion between the two rib portions and facing the end of a flexible or elastic woven fabric in the first cavity, After being arranged in the second cavity so as to pass through the middle part of the woven fabric, a molten synthetic resin material is injected into both cavities and solidified, and between the two rib portions in the cushion body extracted from both dies. The thin continuous portion is cut off.

As described above, when the molten synthetic resin is poured into the first cavity of the mold, the outer peripheral frame portion and the outer peripheral edge of the woven fabric can be simultaneously and integrally connected. Injecting molten synthetic resin in the same way,
Since the reinforcing member can be integrally formed on the woven fabric on the inner diameter side of the outer peripheral frame portion, and thereafter, only a step of separating the thin continuous portion of the reinforcing member is added, the molding process of the cushion body can be simplified. It works.

[Brief description of the drawings]

FIG. 1 is a perspective view of a chair.

FIGS. 2A and 2B show a first embodiment of a manufacturing method, and FIG.
Explanatory drawing of a state in which a woven fabric is arranged between an upper and lower mold having a cavity and a second cavity, (b) is an explanatory view showing a state in which the upper and lower molds are combined, and (c) is taken out of the mold to form a thin continuous connection It is explanatory drawing of the state which isolate | separates a part.

FIG. 3 is an enlarged plan view of a main part of a reinforcing body.

FIG. 4 is a cross-sectional view showing a state in which the cushion body is bent when a load is applied.

5A and 5B show a second embodiment of the manufacturing method, and FIG.
Explanatory drawing of a state where a core material having an outer peripheral edge of a woven fabric fixed thereto is disposed between an upper and lower mold having a cavity and a second cavity.
(B) is an explanatory view showing a state where the upper and lower molds are put together and a molten synthetic resin is injected, and (c) is an explanatory view showing a state where the thin synthetic member is taken out from the mold and cut off.

FIG. 6 is a plan view showing a second embodiment of the reinforcing member in the cushion body.

FIG. 7 is a plan view showing a third embodiment of the reinforcing member in the cushion body.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Chair 2 Cushion body 5 Outer peripheral frame part 6 Woven cloth 7 Reinforcement body 7a Rib part 7b Thin continuous connection part 11 Upper mold 12 Lower mold 13 First cavity 14 Second cavity 17 Cutter

Claims (2)

[Claims] 1. A cushion body in which an end portion of a woven cloth having flexibility or elasticity is integrally connected to an outer peripheral frame portion made of a synthetic resin, wherein the inner peripheral portion of the cushion body has A reinforcing member comprising a pair of rib portions integrally connected to the woven fabric and a thin continuous portion between the two rib portions, and the thin continuous portion of the reinforcing member is cut off together with the woven cloth to form a free edge. A cushion body characterized in that a cushion body is formed. 2. A first cavity corresponding to an outer peripheral frame portion of the cushion body, and a first cavity located at an inner diameter position from the outer peripheral frame portion,
A flexible or resilient woven fabric is provided in the first cavity between a pair of upper and lower molds having a second cavity corresponding to a pair of rib portions and a thin continuous portion between the two rib portions. After facing the end portion, the second cavity is disposed so as to pass through the middle part of the woven fabric, and then the molten synthetic resin material is injected into both cavities and solidified, and the cushion body extracted from both dies is removed. A method of manufacturing a cushion body, comprising separating a thin continuous portion between the rib portions.