JP2006007418A - Seat pad manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a seat pad manufacturing method capable of preventing the occurrence of hardness failure caused by the interposition of compression felt of high rigidity at an unwilling position of a seat main body. <P>SOLUTION: After the compression felt 13 is mounted and fixed in a mold 50 by fitting the pin 65 protruded from the mold 50 in the first through-hole 35 provided to the compression felt 13, a foamable raw liquid U is injected in the mold and foamed to fill the mold 50 not only to foam and mold the pad main body comprising soft foam but also to integrate the compression felt 13 with a part of the back of the pad main body. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a pad for a sheet made of a synthetic resin foam molded article having elasticity such as a flexible polyurethane foam, which is used for a vehicle or furniture sheet.

  In general, a seat pad used as a seat cushion material for a vehicle or the like is made of a molded product of a flexible foam, and is configured as a seat by being assembled to a mounting steel material such as a spring, a frame, or a pipe. In order to ensure a soft sitting comfort, a flexible pad material such as a flexible polyurethane foam is used for such a seat pad, but it does not cause excessive bending when subjected to a heavy load such as when seated. In some cases, it is required to reinforce a part on the back side of the pad to give a sense of rigidity.

By the way, conventionally, there is a case where the back fabric is integrated with the back side of the sheet pad by integral foam molding of the soft foam, but these back fabrics generate abnormal noise due to friction between the pad and the mounting steel material, etc. In order to prevent damage, a relatively flexible one having a basis weight of 20 to 300 g / m ² is used (see, for example, Patent Documents 1 to 3 below). Therefore, it has been difficult to obtain the above-described rigidity with such a backside cloth.

Therefore, instead of the flexible back cloth as described above, or in combination with the flexible back cloth, a highly rigid and thick compression felt may be integrated and reinforced on the back side of the seat pad. However, since such a compression felt has a large basis weight, when it is attached to the upper mold side of the mold, it hangs down by its own weight. In particular, when a compression felt is joined to a part of the back surface cloth, the weight of the compression felt acts on the soft back surface cloth, and the degree becomes large. When foam molding is performed in such a state, a high-rigidity compression felt is interposed at an unintended position of the sheet body, resulting in a problem of hardness failure.
JP-A-6-171002 JP-A-6-171003 JP 2000-62061 A

  The present invention has been made in view of the above points, and prevents a compression felt having a large basis weight from sagging under its own weight when attached to a mold, thereby preventing the occurrence of the above-described hardness failure. An object of the present invention is to provide a method for manufacturing a pad for a sheet.

  The method for producing a pad for a sheet of the present invention includes foaming a pad body made of a flexible foam by mounting a compression felt in a molding die, injecting a foaming stock solution into the molding die and filling with foam, A method for manufacturing a pad for a sheet in which the compression felt is integrated with a part of the back surface thereof, wherein the compression is achieved by inserting a pin protruding from the mold into a first through hole provided in the compression felt. A felt is attached and fixed to the mold.

  In the manufacturing method of the present invention, by inserting a pin protruding from the molding die into the first through hole provided in the compression felt, the compression felt is reliably fixed to the molding die without drooping under its own weight. Therefore, the compression felt can be accurately integrated at a desired position on the back surface side of the pad body, and the occurrence of the above-described hardness failure can be prevented. In this case, since the compression felt is highly rigid and thick, it can be sufficiently fixed by fitting with the pin. Therefore, it is not necessary to return the pin to the pin, and when the sheet pad is taken out of the mold, the pad main body is not caught by the pin and has excellent demolding property.

  In the manufacturing method of the present invention, a flexible back cloth that is integrated with the back face of the pad main body and has a second through hole corresponding to the first through hole. After joining the compression felt to a part, the back cloth is attached and fixed to the mold using back cloth locking means provided on the mold, and the pin is attached to the first and second pins. The compression felt may be fixed to the mold by fitting the first through hole and the pin through the through hole. Even when a compression felt is joined to a part of such a back cloth and the back cloth and the compression felt are provided on the back side of the pad body, the weight of the compression felt does not work on the soft back cloth. Therefore, the back fabric does not hang down, and the same effect as described above can be obtained.

  In this case, the second through hole may be provided with a larger diameter than the first through hole. By providing the first and second through holes in this manner, the first through hole is not blocked by the back surface cloth even if the joining position of the compression felt and the back surface cloth varies. Can be easily inserted, and the manufacturing operation is not hindered.

  In the manufacturing method of the present invention, the pin protruding from the mold is composed of a body portion and a tip portion having a smaller diameter, and the height of the body portion is 1.2 to 1.8 times the thickness of the compression felt. It is preferable that the diameter of the first through hole is equal to the outer diameter of the body portion. By providing the pins in this way, it becomes easy to fit into a highly rigid and thick compression felt, and it is possible to suppress the fall of the compression felt by improving the mounting property.

  According to the sheet pad manufacturing method of the present invention, it is possible to prevent the compression felt having a large basis weight from hanging down due to its own weight when it is attached to the molding die. It is possible to eliminate hardness defects caused by the presence of compression felt.

  Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a perspective view of a sheet pad 10 obtained by a manufacturing method according to an embodiment of the present invention, FIG. 2 is a sectional view of the pad 10, and FIG. 3 is a view in which a compression felt 13 used for the pad 10 is joined. FIG. 4 is a developed view of the back cloth 14, FIG. 4 is a cross-sectional view of the mold 50 during foam molding of the pad 10, and FIG.

  The present embodiment relates to a method of manufacturing a seat pad 10 used for a backrest portion of a front seat of an automobile shown in FIG. The pad 10 for sheet includes a pad main body 12 made of a flexible polyurethane foam, a back surface cloth 14 that is laminated and integrated on the back surface thereof to prevent abnormal sounds and damage to the pad main body 12, and the pad main body 12 and the back surface cloth 14. And a compression felt 13 for providing a desired feeling of rigidity of a desired portion of the pad body, and is assembled to a mounting steel material (not shown) such as a frame.

  The pad main body 12 has an inward flange-like overhang for frame mounting integrally provided on three sides of the pad main body portion 16 constituting the backrest and the upper side and the left and right sides on the back side. It consists of the part 18, and has comprised the outline bag shape as a whole. A through hole 19 for mounting a headrest (not shown) is provided on the upper surface of the pad main body 12.

The compression felt 13 is thicker and more rigid than the back cloth 14, and fibers such as cotton, rayon, nylon, and polyester are arranged in a web or mat shape by an appropriate method. 400 to 1200 g / m ² , more preferably 700, obtained by using and pressing to bond the fibers together, or hot pressing without using a binder and bonding the fibers together by fusion. A press felt or punch carpet of ˜900 g / m ² is cut into a predetermined shape.

  The compression felt 13 is provided with a first through hole 35 for fitting a pin 65 protruding from the core mold 60 of the mold 50. Specifically, a punching hole having an opening diameter that is the same as the outer diameter of the body 65 a constituting the shaft portion of the pin 65 is provided in the center of gravity of the compression felt 13.

  Further, the compression felt 13 is provided with a V-shaped notch 34 as a mark for sewing with the back surface cloth 14 and a broken line cut (perforation) 36 for facilitating along the back surface shape of the pad main body 12. It has been.

As shown in FIG. 2, the back surface cloth 14 is integrated by polyurethane foam foam molding so as to cover the back surface of the pad main body portion 16 and the inner surface of the overhang portion 18. The back fabric 14 can be used without any particular limitation as long as it has excellent flexibility, has an appropriate air permeability, and can prevent the polyurethane foam from seeping out during molding. A nonwoven fabric or woven or knitted fabric with a basis weight of 20 to 300 g / m ² or a laminated composite of these can be used.

  The shape of the base fabric constituting the back fabric 14 is as shown in FIG. 3, and the fabric main body 20 integrated with the back surface of the pad main body 16 and the pad main body 12 extending integrally from both sides thereof. The fabric side surfaces 22 and 22 are integrated with the inner side surfaces of the overhanging portions 18a and 18a on the both sides of the pad, and the overhanging portion 18b on the upper side of the pad main body 12 is integrally extended from the upper side of the fabric main body portion 20. The cloth rear surface portion 24 is integrated with the inner surface.

  The cloth main body portion 20 is provided with a second through hole 25 so as to face the first through hole 35 when the compression felt 13 is joined, and the diameter of the second through hole 25 is the first diameter. It is provided larger than that of the through hole 35. In addition to the second through hole 25 provided in the cloth main body 20, the back cloth 14 has a through hole 26 for a headrest at a position corresponding to the through hole 19 of the pad main body 12, and the back cloth 14. A through-hole 27 is provided for fixing the to the core mold 60.

  The back surface cloth 14 provided as described above is sewn into a bag shape so as to easily conform to the back surface shape of the pad main body 12 and then joined to the compression felt 13. Specifically, when the back cloth 14 and the pad main body 12 are integrated at the lower center portion of the cloth main body 20 in the back cloth 14, the compression felt 13 is disposed so as to be interposed therebetween, and the molding die Before being attached to 50, it is joined by sewing 38 in advance. At that time, the mark hole 30 and the corner portion 32 of the compression felt 13 are arranged so as to correspond to each other, and then sewing 38 is performed along a straight line connecting the horizontal notches 34. Even if there is some variation in the attachment position in the sewing 38, the second through hole 25 provided in the back cloth 14 is provided larger than the first through hole 35 provided in the compression felt 13. The back cloth 14 does not block the first through hole 35.

  In addition, the joining means of the cloth main body 20 and the compression felt 13 is not limited to sewing, and may be gluing, heat sealing, or the like.

  As described above, the back cloth 14 that is sewn in a bag shape and the compression felt 13 is joined to the cloth main body 20 is mounted in the molding die 50 shown in FIG. Are laminated and integrated.

  As shown in the figure, the mold 50 is rotatable via a lower mold 52 that is recessed so as to mold the surface side portion of the pad main body 12 and a hinge portion 54 that is disposed on one side of the lower mold 52. And an upper die 56 that opens and closes the upper surface opening of the lower die 52. The upper die 56 is a die that molds the back surface side of the pad main body 12, and a cavity 58 that is a foaming space corresponding to the pad shape is formed between the lower die 52 and the lower die 52 by closing the upper surface opening of the lower die 52. . The upper die 56 is provided with a core die 60 for molding the overhanging portion 18. The core mold 60 is provided so as to be movable up and down by a drive device 62 provided on the upper mold 56. When the core mold 60 is moved downward by the drive device 62, the core mold 60 is detached from the upper mold 56 and the mold. It is designed to be opened.

  The core mold 60 includes a protrusion 66 for forming the through hole 19 of the pad main body 12, a fastener 64 for fixing the back cloth 14, and a pin 65 for fixing the compression felt 13. As will be described later, in the present embodiment, the convex portion 66 and the fastener 64 serve as back surface cloth locking means. Specifically, the fastener 64 is a mushroom-shaped protrusion, and has a shape that can hold the soft back cloth 14. Further, as shown in FIG. 5, the pin 65 has an outer diameter that is the same as the diameter of the first through hole 35, and has a thickness of the compression felt 13 (depth of the first through hole 35). A cylindrical or columnar body 56a having a height of 2 to 1.8 times and a substantially hemispherical tip 56b having a smaller diameter than the cylindrical body 56a.

  When foam-molding the sheet pad 10 using this mold 50, first, the compression felt 13 faces the cavity 58 on the back cloth 14 in which the compression felt 13 is bonded into the mold 50 as described above. Wear as follows. Specifically, as shown in FIG. 4, the cloth rear surface portion 24 having a bag shape while passing the convex portion 66 through the through hole 26 provided in the boundary portion between the cloth main body portion 20 and the cloth rear surface portion 24. The cloth side surface portion 22 is put on the core mold 60 site that forms the overhanging portion 18, and the back surface cloth 14 is fixed by engaging the through hole 27 provided in the cloth side surface portion 22 and the fastener 64. Then, the pin 65 is passed through the first and second through holes 35 and 25 provided in the compression felt 13 and the back cloth 14, respectively, and the compression felt 13 is cavityd by fitting the first through hole 35 and the pin 65. Set in 58 on the upper die 56 side.

  Next, after injecting the polyurethane foam foaming stock solution U into the cavity 58 using an unillustrated injector, the upper mold 56 is closed to seal the cavity 58. The foaming stock solution U is preferably poured into the lower mold 52 as evenly as possible. Thereby, the foaming stock solution U fills the cavity 58 while foaming.

  The foam body solution U is foamed and filled in the cavity 58 in this way, whereby the pad body 12 made of polyurethane foam is foam-molded, and the pad body 12 is provided with a compression felt 13 on the back surface of the pad body portion 16. The back surface cloth 14 is integrated with the back surface. After the molding, the upper die 56 is opened, the core die 60 is further detached from the upper die 56, the die is opened, and then the mold is removed, whereby the sheet pad 10 shown in FIGS.

  Thus, according to the above-described embodiment, when the back surface cloth 14 to which the compression felt 13 is joined is attached to the core mold 60, the back surface cloth 14 is fixed by the back surface cloth locking means 64, 66, and Since the compression felt 13 is also fixed by the pin 65, the compression felt 13 attached to the core mold 60 does not hang down during foam molding, and the compression felt 13 is interposed at an unintended position of the pad body 12. The hardness defect resulting from that can be suppressed.

  Further, the pin 56 includes a barrel portion 56a having the same outer diameter as the opening diameter of the first through hole 35, and a substantially hemispherical tip portion 56b having a smaller diameter than the barrel portion 56a, thereby achieving high rigidity. Therefore, even if the compression felt 13 is thick, it is easy to fit, and the pin 65 is tightly fitted to the compression felt 13 with high rigidity and no gap, so that the compression felt 13 falls off due to its own weight. In addition, when the molded pad main body 12 is taken out from the mold 50, it does not get caught by the pins 56 and is excellent in demolding. Is easier to do.

  In the present embodiment, the opening shape of the first through hole 35 provided in the compression felt 13 and the cross-sectional shape of the pin 65 are provided in a circular shape, but the present invention is not limited to this, and the first through hole 35 is not limited thereto. As long as the pin 65 and the pin 65 can be fitted to each other and the compression felt 13 can be fixed, it may be oval or polygonal.

  Further, the present embodiment is a method for manufacturing a back pad used for a backrest portion of a front seat of an automobile in which a compression felt and a back cloth are integrated on the back side of the pad body. The seat pad is not limited to the intended use. For example, a seat pad having only a compression felt integrated on the back side of the pad body, a seat portion of a front seat of an automobile, or a seat portion or backrest of a rear seat The present invention can also be applied to a sheet pad used for a part.

It is a perspective view of the pad for sheets obtained by the present invention. It is the II-II sectional view taken on the line of FIG. It is an expanded view of the back surface fabric to which the compression felt was joined. It is sectional drawing of the shaping | molding die at the time of foam molding of the pad for sheets. It is a principal part enlarged view of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Seat pad 12 ... Sheet main body 13 ... Compression felt 14 ... Back cloth 25 ... 2nd through-hole 35 ... 1st through-hole 50 ... Mold 64 ... Fastener 65 ... Pin 66 …… Convex

Claims (4)

A compression felt is mounted in the mold, and the foam body is foamed and filled by injecting the foaming stock solution into the mold, and the compression felt is integrated into a part of the back surface of the pad body. A method of manufacturing a pad for a sheet to be converted,
A method for producing a pad for a sheet, wherein the compression felt is attached and fixed to the molding die by inserting a pin protruding from the molding die into a first through hole provided in the compression felt.   The compression felt is joined to a part of the back surface cloth using a back surface cloth integrated with the back surface of the pad body and having a second through hole corresponding to the first through hole. Then, the back cloth is attached and fixed to the mold using back cloth locking means provided in the mold, and the pin is passed through the first and second through holes. The method for manufacturing a seat pad according to claim 1, wherein the compression felt is fixed to the mold by fitting the through hole and the pin.   The method for manufacturing a pad for a sheet according to claim 2, wherein the second through hole is provided with a larger diameter than the first through hole. The pin is composed of a body part and a tip part having a smaller diameter than the body part, and the height of the body part is set to 1.2 to 1.8 times the thickness dimension of the compression felt. 4. The method for manufacturing a pad for a sheet according to any one of claims 1 to 3, wherein the diameter of the sheet is set equal to the outer diameter of the body portion.

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