JP2002172038A - Seat pad made of foamed resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a seat pad made of foamed resin, which is improved in appearance without increasing manufacturing cost. SOLUTION: This seat pad 10 made of foamed resin for a seat cushion is made by superposing a surface layer pad 12 made of foamed resin with relatively low hardness onto the seating area with recess cross section on the pad body made of foamed resin. The surface layer pad 12 is integrated with the pad body 11 via integral hinge parts 14, 14a formed on the edge part of the surface layer pad 12 so as to be superposed onto the pad body 11 by folding back.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed resin seat pad in which a relatively low surface layer pad is superposed on a pad body having a concave cross section of a seat cushion or a seat back and further covered with a skin. It is about.

[0002]

2. Description of the Related Art A foam resin seat pad 1 of a vehicle seat, for example, as shown in FIG. 4, of a seat cushion has a foam resin pad body 1a having side pad portions 1b on both sides.
As shown in FIGS. 5A and 5B, a concave portion which is deepest at the center in the lateral direction is formed in the seating area to improve sitting comfort, and the foam resin surface layer pad 2 having relatively low hardness.
5C is integrally foamed or adhered, and furthermore, as shown in FIG. 5C, locking of the locking member 6 having the skin 4 attached to the skin hanging wire 5 embedded in the H-shaped groove 9 of the pad body 1a. To hang the cover.

[0003]

Therefore, as shown in the figure, a gap 4a is formed between the surface pad 2 and the skin 4 that are concave, and the skin 4 floats, so that wrinkles are easily generated with time, and the appearance is impaired. In addition, since there is a need for another mold for the surface layer pad 2 at the time of manufacturing, there is room for improvement in that the manufacturing cost is increased. Furthermore, surface pad 2
In order to assemble the epidermis 4 while crushing the lateral end portions (in FIG. 5C, the two-dot chain line shows the state before being crushed), the workability was poor and the epidermis was easily displaced in the lateral direction. Such a problem is common to a seat pad of a seat back in which a back support area of a pad body has a concave cross section.

SUMMARY OF THE INVENTION In view of the foregoing, it is an object of the present invention to provide a foam resin sheet pad of the kind mentioned at the beginning, which can improve the appearance without increasing the cost.

[0005]

According to the present invention, there is provided a seating region or back having a concave cross section of a foamed resin pad body of a seat cushion or a seat back according to the present invention. In the contact area, a foamed resin surface layer pad having relatively low hardness is overlapped, and in the foamed resin seat pad further covered by the skin,
The surface pad is integrated with the pad body via an integral hinge formed at the end of the surface pad so that the surface pad is overlapped with the pad body by folding.

[0006] The surface pad having relatively low hardness is folded toward the pad body having a concave cross section with the integral hinge portion as a fulcrum, and the surface thereof is covered with the skin, whereby the integral hinge portion or the surface layer is covered. The skin comes into close contact with the elastic reaction force of the pad.

[0007]

1 to 3 illustrate a foamed resin seat pad for a vehicle seat cushion according to an embodiment of the present invention. FIG. 2 shows an injection molding die for producing the foamed resin seat pad 10.
Surface cavities 22, 22a are provided on both sides of the front and back of the cavity 21 for the pad body 1a in a communication state. These cavities have the same thickness over the entire area, and have an H-shaped groove 9 along the side pad portion 11a.
Two flat surface pads 1 separated by horizontal grooves 9a and having a width corresponding to the distance between the vertical grooves 9b on both sides.
2, 12a is formed by foam molding. Further, a convex portion 20a for the H-shaped groove 9 is also formed. Further, on both sides of the cavity 21 in the depth direction as viewed in the same drawing,
A cavity for the side pad portion 11a is formed (not shown). The surface layer pad 1 is provided at a corner portion of the upper mold 27 which bends from the cavity 21 to the cavities 22 and 22a.
A convex portion 27a for forming a thin integral hinge portion 14, 14a is formed at the opposite end of the lateral groove side of 2, 2a.

In injection molding, the H-shaped groove 9 of the lower mold 20 is used.
The wire 5 is set in a region where the resin is formed, and a relatively soft urethane raw material resin 24 is injected into the bottoms of the front cavity 22 and the rear cavity 22a.
A relatively hard urethane raw material resin 23 is injected into the central portion of the substrate, and then the upper mold 27 is set to simultaneously perform foam molding.

As a result, the wire pad 5 is integrated with the pad body 1a, and the end portions of the surface pads 12, 12a are formed through the integral hinge portions 14, 14a formed at the corners of the upper die 27. Is molded into a state integrated with the pad body 11 as shown in FIG.

At the time of assembling the seat pad 10, as shown in FIG. 3, both surface pads 12, 12a are directed toward the pad body 11 with the integral hinge portions 14, 14a as fulcrums, as indicated by a two-dot chain line in FIG. Fold into the epidermis 4
Then, the wire 5 is hooked onto the wire 5 with the locking tool 6 (see FIG. 3C). As a result, the skin 4 is set in a state where the surface pads 12, 12a are tightly attached to each other in a horizontal plane by the slight elastic reaction force of the surface pads 12, 12a themselves or the integral hinge portions 14, 14a. Therefore, the surface pads 12, 1
The problem that 2a rises and is crushed by the epidermis 4 is also solved,
It is set easily and looks good.

A space 19 is generated between the seating areas of the surface pads 12, 12a and the pad body 1a in the state covered by the skin 4, as described above. Surface pad 1 when not in use
It returns to a flat position due to the elasticity of 2, 12a.

Incidentally, a rigidity sheet such as a nonwoven fabric is integrally formed on the integral hinge portions 14 and 14a to impart rigidity to the connection portion, or a surface of the central portion of the pad body 11 is reinforced in a similar manner. Thus, the posture of the seat pad 10 at the time of cornering or the like can be stabilized.

The present invention is also applicable to a seat pad made of a foamed resin for a seat back, and has a concave back portion in the cross section of the pad body, and a longitudinal center of an H-shaped groove at both longitudinal ends of the pad body. One end of each of the two surface pads separated by the portion can be integrated via an integral hinge portion.

However, in the above-mentioned seat cushion and seat back, depending on the shape of the wire mounting groove, one surface layer pad may be formed, and only one end in the vertical direction may be connected by an integral hinge. Alternatively, if the mold structure is tolerated, the lateral ends can be integral hinged. The surface layer pad is not necessarily a flat plate but may be formed, for example, slightly outwardly in consideration of designability.

[0015]

According to the first or second aspect of the present invention,
Since the back surface of the skin is in close contact with the surface layer pad, wrinkles do not occur with time in the skin, deformation that may occur when the wire is attached is avoided, and the appearance is improved. The surface layer pad is foam-molded simultaneously with the pad body in one mold, which is advantageous in manufacturing cost. When the conventional surface pad is integrally formed with the pad body, the problem that the impregnated layer becomes hard and the sitting comfort is deteriorated is also solved. According to the third aspect of the present invention, even when the H-shaped groove for wire attachment is formed in the foam resin sheet pad, the surface layer pad is easily integrated.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a state before assembling a skin of a foam resin seat pad for a seat cushion according to an embodiment of the present invention.

FIG. 2 is a schematic sectional view of a mold for foam-molding the foam resin sheet pad.

3 shows a cross-sectional structure of the foamed resin sheet pad. FIG. 3A is a cross-sectional view taken along line AA of FIG. 3, and FIG.
Fig. C is an enlarged cross-sectional view of a side surface assembling portion.

FIG. 4 is a perspective view showing a state in which a conventional foam resin seat pad for a seat cushion has not yet been assembled to a skin.

5 shows a cross-sectional structure of a conventional seat cushion, FIG. 5A is a cross-sectional view taken along line CC of FIG. 4, FIG. 5B is a cross-sectional view taken along line DD, and FIG. It is an expanded sectional view of an attachment part.

[Explanation of symbols]

 Reference Signs List 4 skin 9 H-shaped groove 10 seat pad 11 pad body 11a side pad portion 12, 12a surface pad 20 lower mold 21 pad body cavity 22, 22a surface pad cavity 27 upper mold

Claims (3)

[Claims] 1. A foamed resin seat pad in which a foamed resin surface layer pad having relatively low hardness is overlapped with a seating region having a concave cross section in a foamed resin pad body of a seat cushion, and further covered with a skin. A foamed resin sheet, wherein the surface layer pad is integrated with the pad body via an integral hinge portion formed at an end of the surface layer pad so that the surface layer pad is folded over the pad body. pad. 2. A foamed resin foam which is covered with a foamed resin surface layer pad having a relatively low hardness is placed on a back support area having a concave cross section of a foamed resin pad body of a seat back, and further covered with a skin. In the resin seat pad, the surface pad is integrated with the pad body via an integral hinge portion formed at an end of the surface pad so that the surface pad is overlapped with the pad body by folding. Foam resin seat pad. 3. The surface pad is separated by a horizontal groove of an H-shaped groove for embedding a wire for suspending the skin of the pad body, and the width corresponds to a separation distance between the vertical grooves on both sides of the H-shaped groove. 2. The pad body is integrated with both ends of the pad body in the vertical direction via integral hinge portions formed at the end of the surface layer pad on the side opposite to the lateral groove. 3. Or a sheet pad made of a foamed resin according to claim 2.