JP2006001147A - Manufacturing method of seat pad - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To eliminate the molding failure caused by the reinforcing fabric integrated with the protruded part toward the back of a pad edge part while ensuring demolding properties after foam molding. <P>SOLUTION: In this manufacturing method of the seat pad 10 equipped with a pad main body 12 and the reinforcing fabric 14 integrated with the back thereof and constituted so that the protruded part 22 is provided on the back side of a side part 18 and the edge part 14a of the reinforcing fabric 14 is integrated along the inside wall surface 22a of the protruded part, the edge part 14a of the reinforcing fabric 14 is inserted in the gap between the inside wall surface 54b of the recessed part 54 of an upper mold and the pin 56 provided to the bottom of the recessed part 54 to be held between them when the reinforcing fabric 14 is attached to the wall surface of the upper mold 44. Further, a sewing part 36 is provided to the reinforcing fabric part corresponding to the root part 22b of the protruded part 22 by pinch sewing and the sewing margin 37 of the sewing part 36 is formed so as to provide the edge part 14a outside from the sewing part 36 along the inside wall surface 54b of the recessed part 54 toward the pad main body 12. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a seat pad used as a seat cushion material for a vehicle or the like.

  In general, a seat pad used as a seat cushion material of an automobile or the like is made of a flexible foam molded product such as a flexible polyurethane foam. Such a seat pad is configured as a seat by being assembled to the seat frame, but there is a problem that abnormal noise is generated or damaged due to vibration with the seat frame or friction with the seat frame during seating. Therefore, in order to prevent the occurrence of such abnormal noise or to protect and strengthen from damage, a reinforcing fabric such as a nonwoven fabric as a backing material is integrally formed on the back surface of the pad body made of flexible foam by foam molding of the flexible foam. (For example, refer to Patent Documents 1 to 3 below).

FIG. 6 is a cross-sectional view of a sheet pad provided with such a reinforcing cloth. As shown in the figure, the sheet pad 100 is formed in a bulging shape upward at the main portion 101 at the center in the width direction and on the left and right sides thereof. The side portion 102 is provided with a protruding portion 103 that protrudes toward the back surface side. A reinforcing cloth 110 is laminated and integrated from the back surface 101 of the main portion 101 to the inner wall surface 103 a of the protruding portion 103 in the side portion 102.
JP-A-6-171002 JP-A-6-171003 JP 2000-71838 A

  In the pad structure provided with the protrusion 103 on the back surface side of the pad edge as described above, when the edge 110a of the reinforcing cloth 110 is laminated and integrated with the inner wall surface 103a of the protrusion 103, the following is performed. Problems can arise. That is, at the time of foam molding of the pad main body, the reinforcing cloth 110 is attached to the mold surface of the upper mold and is integrated with the pad main body by foam filling the foam stock solution in the cavity between the upper mold and the lower mold. However, at that time, the edge 110a of the reinforcing cloth integrated with the inner wall surface 103a of the protruding portion is not locked to the mold surface of the upper mold, and the mold surface is brought into contact with the foam filling of the flexible foam. It is designed to be pressed. However, the edge portion 110a of the reinforcing cloth is likely to spread outward as indicated by a two-dot chain line X in FIG. 6, so that the flexible foam wraps around the back side of the reinforcing cloth and the flexible foam is exposed to the back side. In some cases, molding defects occur. In addition, since the protruding portion 103 is a foaming terminal that is finally filled during molding, the force pressing the edge X of the reinforcing cloth spreading outwardly against the mold surface does not sufficiently act, Foaming may be completed in this state, and in that case, a molding defect occurs in which the thickness of the protrusion 103 is reduced.

  In order to solve such a problem, a pin projecting laterally from a mold surface forming the inner wall surface 103a of the projecting portion is provided, and a through hole is provided in the edge portion 110a of the reinforcing cloth, and the above-described hole is provided in the through hole. It is conceivable that the edge 110a of the reinforcing cloth is aligned with the mold surface by inserting a pin. However, in such a pin, the protrusion 103 of the pad is damaged by the pin at the time of demolding after foam molding. become.

  The present invention has been made in view of the above points, and it is possible to eliminate molding defects caused by the reinforcing cloth integrated on the back surface side of the projecting portion while ensuring demoldability after foam molding. It is an object of the present invention to provide a method for manufacturing a sheet pad that can be used.

  The present invention comprises a pad main body made of a flexible foam and a reinforcing cloth laminated and integrated on the back surface of the pad main body by foam molding of the soft foam, and at least one edge of the peripheral edge of the pad main body. Further, the present invention relates to a method for manufacturing a pad for a sheet in which a protrusion protruding to the back surface side is provided, and the edge of the reinforcing cloth is laminated and integrated along the inner wall surface of the protrusion. And in the 1st manufacturing method concerning the present invention, it consists of the 1st type provided with the crevice for shape | molding the said protrusion part, and the 2nd type | mold which forms a cavity between the said 1st type | mold, The said crevice The reinforcing cloth is detachably attached to the mold surface of the first mold using a molding die provided with a pin protruding from the bottom surface (that is, the deepest portion) along the inner wall surface of the recess. The edge of the cloth is inserted and held between the inner wall surface of the recess and the pin, and the pad main body is molded by foaming the foaming stock solution in the cavity to which the reinforcing cloth is attached. And

  In this way, pins that protrude from the bottom surface of the concave portion for forming the protruding portion along the inner wall surface of the concave portion are provided, and the edge of the reinforcing cloth is inserted and held between these pins and the inner wall surface of the concave portion. Since the reinforcing cloth is attached to the first mold, foam molding can be performed in a state where the edge of the reinforcing cloth is along the inner wall surface of the recess. For this reason, it is possible to prevent the flexible foam from wrapping around the back side of the reinforcing cloth, and it is also possible to eliminate a molding defect that the thickness of the protruding portion is reduced. In addition, if the pin has the above structure, it protrudes in the direction in which the protruding portion is removed, so that the removal property is not impaired.

  In the second manufacturing method according to the present invention, there is provided a sewing portion formed by overlaying and sewing two cloth portions on a reinforcing cloth portion corresponding to the base portion of the protruding portion, and forming the protruding portion. The reinforcing cloth is detachably attached to the mold surface of the first mold, using a mold composed of a first mold having a concave portion and a second mold that forms a cavity between the first mold and the first mold. At that time, the seam allowance of the sewing portion is directed toward the pad main body, the edge portion outside the sewing portion is set along the inner wall surface of the concave portion, and the foaming stock solution is formed in the cavity to which the reinforcing cloth is thus attached. The pad main body is molded by foaming the pad.

  As described above, the reinforcing cloth is provided with a sewing portion so that the edge of the reinforcing cloth can be easily aligned with the inner wall surface of the concave portion of the first mold, so that the edge of the reinforcing cloth is prevented from spreading outward during foam molding. Further, it is possible to prevent the flexible foam from wrapping around the back side of the reinforcing cloth, and it is possible to eliminate the molding defect that the thickness of the protruding portion is reduced.

  In the present invention, it is preferable to combine the first manufacturing method and the second manufacturing method described above, that is, in the first manufacturing method, two cloths are provided on the reinforcing cloth portion corresponding to the base portion of the protruding portion. When a sewing part is formed by overlapping and stitching the parts, and when the reinforcing cloth is attached to the mold surface of the first mold, the seam allowance of the sewing part is directed toward the pad main body side, and the sewing part is more than the sewing part. It is preferable that the outer edge is inserted between the inner wall surface and the pin so as to be along the inner wall surface of the recess. Thereby, the above-mentioned molding defects can be solved more reliably.

  Moreover, in this invention, it is preferable that the said sewing part is thing by knob sewing. In the case of knob sewing, it can be formed simply by sewing a single piece of cloth, so the number of sewing man-hours can be reduced, and there is no break in the reinforcing cloth in the sewing part, so flexible foam Can be reliably prevented from leaking to the back side of the reinforcing cloth through the sewing portion.

  As described above, the sheet pad manufacturing method according to the present invention eliminates molding defects caused by the reinforcing cloth integrated on the back surface side of the protruding portion while ensuring demoldability after foam molding. can do.

  Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings.

  FIG. 1 is a view showing a forming die 10 used when forming a sheet pad 10 according to the embodiment, FIGS. 2 and 3 are views showing the sheet pad 10, and FIGS. 4 and 5 are reinforcing cloths 14. It is a figure.

  The seat pad 10 is a seat cushion pad that constitutes a seating portion in a front seat of an automobile. As shown in FIGS. 2 and 3, a pad body 12 made of a highly elastic flexible polyurethane foam and a back surface integrated with the pad body 12 are integrated. And a reinforced reinforcing cloth 14.

  The pad main body 12 is composed of a main portion 16 in the center in the width direction for receiving the occupant's buttocks and thighs from below, and a pair of left and right side portions 18 and 18 formed in a protruding shape on both sides in the width direction. The portion 16 and the side portion 18 are partitioned by a pair of left and right skin suspending vertical grooves 20 and 20 formed in the pad surface (pad upper surface) and extending in the front-rear direction. As shown in FIG. 3A, the side portion 18 rises upward from the longitudinal groove 20 outward, and is formed in a substantially reverse cross-sectional shape that hangs downward through a curved top portion 18a at the outer end. ing. As a result, the side portion 18 is provided with a protruding portion 22 that protrudes toward the back surface at the edge of the pad main body 12, and is recessed upward on the back surface side of the side portion 18 inside the protruding portion 22. A formed concave portion 24 is provided. Further, as shown in FIG. 2, the main portion 16 is provided with a concave portion 26.

  The reinforcing cloth 14 is attached to the entire back surface of the main portion 16 excluding the recessed portion 26 and the back surface including the recessed portion 24 of the side portion 18. More specifically, the reinforcing cloth 14 is attached from the back surface of the main portion 16 to the inner surface of the concave portion 24 on the back surface side of the side portion 18, and as shown in FIG. The edge portions 14a on both sides are laminated and integrated with the inner wall surface 22a of the protruding portion 22, and the edge portion 14a terminates at the lower end portion of the inner wall surface 22a of the protruding portion.

  Here, the reinforcing cloth 14 serves to protect the pad body 12 and to suppress the generation of a rubbing sound with the seat frame (not shown), and can play such a role. Any non-woven fabric, woven or knitted fabric, or a laminated composite of these can be used without particular limitation. Generally, a coarse blanket, a cold chill, a felt, or the like is used.

  As shown in FIG. 4, the reinforcing cloth 14 is composed of a base cloth cut into a shape corresponding to the main portion 16 of the pad main body 12 and the back surfaces of the left and right side portions 18, 18. An opening 28 corresponding to the concave portion 26 is provided, and a through hole 30 through which a mounting pin is inserted when the reinforcing cloth 14 is locked to an upper mold surface described later is provided.

  In addition, V-shaped cuts 32 are provided on the left and right sides of the edge corresponding to the front edge of the pad main body 12, and the opposing edges are sewn together by a sewing part 34. . Further, as shown in FIGS. 3B and 5, the inner and outer two fabric portions 14 a and 14 b are folded on the reinforcing fabric portion corresponding to the base portion 22 b of the projecting portion 22 by pinching and folded. A sewing portion 36 is provided that is sewn in the vicinity of the curve 38, and this sewing portion 36 is formed to extend in the front-rear direction along the base portion 22b of the protruding portion 22 (see FIG. 4). The sewing portion 36 is integrated with the pad main body 12 such that a seam allowance 37 is embedded in the pad main body 12 side.

  As shown in FIG. 1, a molding die 40 for molding the seat pad 10 is formed as a second lower mold 42 that is held approximately horizontally and molds the surface side of the pad, and the lower die 42 is opened and closed. An upper mold 44 is provided as a first mold that is provided so as to mold the back side of the pad, and a cavity 46 as a foaming space is formed between the lower mold 42 and the upper mold 44.

  The lower mold 42 is provided with a shelf-like portion 48 at the center in the width direction for forming the main portion 16 and a recessed portion 50 that is recessed downward to form the side portion 18 on both the left and right sides thereof. On both the left and right sides of the upper mold 44 corresponding to the recess 50, there are provided projecting parts 52 projecting downward for molding the recessed part 24, and on the outer side, an upper part for molding the projecting part 22 A recess 54 is provided that sinks into the recess.

  The bottom surface 54a of the recess 54 of the upper mold 44 (that is, the deepest part, the ceiling surface as the cavity 46) 54a is located along the inner wall surface 54b (that is, on the wall surface 54b) in the vicinity of the inner wall surface 54b of the recess 54. A rod-like pin 56 protruding downward (substantially in parallel) is provided. The pin 56 sandwiches and holds the edge portion 14a of the reinforcing cloth 14 between the inner wall surface 54b, and the interval between the pin 56 and the inner wall surface 54b makes it easy to insert the edge portion 14a of the reinforcing cloth between them. And the dimension is set such that the inserted edge 14a does not fall off. The pins 56 can be provided at only one location in the front-rear direction of the recess 54, but are preferably provided at a plurality of locations at predetermined intervals in order to hold the edge portion 14a of the reinforcing cloth more reliably.

  The manufacturing method of the sheet pad 10 is as follows.

[1] The base cloth-shaped reinforcing cloth 14 shown in FIG. 4 is manufactured by punching or the like, the opposing edges of the notch 32 are sewn together by a sewing part 34, and a sewing part 36 is provided by the above-described knob sewing.

[2] The obtained reinforcing cloth 14 is put on the mold surface of the upper mold 44, and a plurality of mounting pins (not shown) protruding from the upper mold 44 are individually passed through the through holes 30 of the reinforcing cloth 14. The reinforcing cloth 14 is detachably attached to the upper mold 44. At that time, the seam allowance 37 of the sewing portion 36 is directed toward the pad main body 12 (polyurethane foam side), and the edge portion 14a outside the sewing portion 36 is aligned with the inner wall surface 54b of the concave portion 54 of the upper mold 44. Then, it is inserted and held between the inner wall surface 54 b and the pin 56.

[3] Next, a polyurethane stock solution 58 as a foamed resin stock solution is supplied to the lower mold 42, and the upper mold 44 is put on the lower mold 42 to close the mold. Thereby, the polyurethane stock solution 58 is foam-filled in the cavity 46 formed between the upper mold 44 and the lower mold 42, and the sheet pad 10 in which the reinforcing cloth 14 is laminated and integrated on the back surface is molded.

[4] Thereafter, the upper die 44 is opened and removed to obtain the seat pad 10 shown in FIGS.

  In the manufacturing method of this embodiment, the pin 56 having the above-described configuration is provided in the concave portion 54 of the upper mold 44, and the edge portion 14 a of the reinforcing cloth 14 is inserted between the pin 56 and the inner wall surface 54 a of the concave portion 54. Since it was made to hold | maintain, foam molding can be performed in the state in which the edge part 14a of the reinforcement cloth was put along the inner side wall surface 54a of the recessed part. Moreover, by providing the sewing portion 36 at the reinforcing cloth portion corresponding to the base portion 22b of the protruding portion 22, the outer reinforcing cloth edge portion 14a can be easily along the inner wall surface 54b of the recess. As described above, it is possible to prevent the edge portion 14a of the reinforcing cloth 14 from spreading outward during foam molding, thereby preventing the polyurethane foam from wrapping around (leaching out) the back side of the reinforcing cloth 14, and the protruding portion. The molding defect that the thickness of 22 becomes thin can also be eliminated. In addition, since the pin 56 having the above-described configuration protrudes in the mold release direction of the protrusion 22, the mold release property is not impaired.

  Moreover, in the said embodiment, since the sewing part 36 is thing by pinch sewing, the man-hour of a sewing work can be reduced, and since there is no cut | interruption of the reinforcement cloth 14 in the sewing part 36, a polyurethane foam is sewn. Leakage to the back side of the reinforcing fabric 14 through the portion 36 can be reliably prevented. In the present invention, instead of such tab sewing, a sewing part may be formed by stitching two cloth parts facing each other in a folded shape after providing a cut as in the sewing part 34, or alternatively, It can also be set as the sewing part which piled up the cloth piece of another body in the shape of folding, and was sewn.

  In the sheet pad 10 obtained in this way, as shown in FIG. 3B, a long and narrow hole by the pin 56 is provided on the distal end surface of the protruding portion 22. Since it is a minute hole provided at predetermined intervals in the longitudinal direction, it does not affect the characteristics of the pad, and since it is provided on the back side, there is no problem in appearance.

  Moreover, although the said embodiment demonstrated the case where the shaping | molding defect about the reinforcement cloth edge part 14a affixed on the back surface in the protrusion parts 22 and 22 provided in the back surface of the side parts 18 and 18 of the right and left both sides was eliminated. In the present invention, it can be similarly applied to the protruding portion at any edge of the peripheral edge of the pad body. For example, it may be applied to only one side portion, or alternatively, the front edge portion of the pad body. It can also be applied to a protruding portion on the rear surface side at the rear edge portion.

  Furthermore, in the above-described embodiment, the molding defect is improved by both the pin 56 and the sewing portion 36. However, the molding defect can be improved by only one of the measures, and such an aspect is provided in the present invention. Is also included. Moreover, in the said embodiment, although the seat cushion pad for motor vehicles was demonstrated, it can also apply to pads other than a seat cushion pad, for example, the seat back pad used for a backrest part, and the pad of the seats other than motor vehicles It is also possible to apply to.

It is sectional drawing at the time of manufacture of the pad for sheets which concerns on one Embodiment of this invention. It is a longitudinal cross-sectional view in the front-back direction of the sheet pad. (A) is the longitudinal cross-sectional view in the width direction of the pad for sheets, (b) is the principal part enlarged view. It is a top view of the reinforcement cloth used for the pad for the sheet | seat. It is a principal part expanded sectional view of the reinforcement cloth. It is a partial expanded sectional view of the conventional sheet pad.

Explanation of symbols

10 …… Seat Pad 12 …… Pad Body 14 …… Reinforcement Cloth 14a …… Reinforcement Cloth Edge 22 …… Protrusion 22a …… Protrusion Inside Wall 22b …… Base Root 36 …… Sewing 37… Seam allowance 40 …… Molding die 42 …… Lower die (second die)
44 …… Upper mold (first mold)
46 …… Cavity 54 …… Recess in upper mold 54a …… Bottom surface of recess 54b …… Inner wall surface of recess 56 …… Pin 58 …… Polyurethane stock solution

Claims (4)

A pad body made of flexible foam, and a reinforcing cloth laminated and integrated on the back surface of the pad body by foam molding of the soft foam, and on the back surface side at least one edge of the peripheral edge of the pad body A method of manufacturing a pad for a sheet, wherein a protruding portion that protrudes is provided, and an edge portion of the reinforcing cloth is laminated and integrated along the inner wall surface of the protruding portion,
It consists of the 1st type | mold provided with the recessed part for shape | molding the said protrusion part, and the 2nd type | mold which forms a cavity between the said 1st type | mold, and protrudes along the inner wall surface of the said recessed part from the said bottom face Using a mold with pins,
The reinforcing cloth is detachably attached to the mold surface of the first mold, and at that time, the edge of the reinforcing cloth is inserted and held between the inner wall surface of the recess and the pin,
In this way, the pad main body is formed by foaming the foaming stock solution in the cavity to which the reinforcing cloth is attached. A sewing part is formed by overlaying and sewing two cloth parts on the reinforcing cloth part corresponding to the base part of the protruding part,
When attaching the reinforcing cloth to the mold surface of the first mold, the seam allowance of the sewn portion is directed toward the pad main body so that the edge portion outside the sewn portion is along the inner wall surface of the recess. The sheet pad manufacturing method according to claim 1, wherein the sheet pad is inserted between the inner wall surface and the pin. A pad body made of flexible foam, and a reinforcing cloth laminated and integrated on the back surface of the pad body by foam molding of the soft foam, and on the back surface side at least one edge of the peripheral edge of the pad body A method of manufacturing a pad for a sheet, wherein a protruding portion that protrudes is provided, and an edge portion of the reinforcing cloth is laminated and integrated along the inner wall surface of the protruding portion,
Providing a sewing part formed by overlaying and stitching two cloth parts on the reinforcing cloth part corresponding to the base part of the protruding part;
Using a mold comprising a first mold having a recess for molding the protrusion and a second mold forming a cavity with the first mold,
The reinforcing cloth is detachably attached to the mold surface of the first mold. At this time, the seam allowance of the sewn portion is directed toward the pad main body, and the edge portion outside the sewn portion is aligned with the inner wall surface of the recess. Let
In this way, the pad main body is molded by foaming the foaming stock solution in the cavity to which the reinforcing cloth is attached, and the pad main body is formed.   4. The method of manufacturing a pad for a sheet according to claim 2, wherein the sewing part is formed by knob sewing.

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