JP2006315348A - Method for producing pad for sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a pad for a sheet capable of arranging a magnetic member simply and accurately in a predetermined position of reinforced cloth. <P>SOLUTION: The method for producing the pad 10 for the sheet including the reinforced cloth 30 integrated into a pad body 12 and the back face thereof, having a protrusion part 22 on the back face side of a side part 18, and integrated with the cloth side edge part 32 of the reinforced cloth 30 along the inner side wall face 22a of the protrusion part comprises when in a first mold 45, a permanent magnet 56 arranged on a mold face for molding the inner side wall face 22a of the protrusion part and a magnetically attracting magnetic member 38 are arranged on the cloth side edge part 32, providing a punched hole 37 in the predetermined position of the cloth side edge part 32 corresponding to a position where the permanent magnet 56 is arranged, and arranging the magnetic member 38 on the cloth side edge part 32 by marking the punched hole 37. <P>COPYRIGHT: (C)2007,JPO&INPIT

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 formed of a flexible flexible foam molded product made of a flexible polyurethane foam or the like. Such a seat pad is configured as a seat by being assembled to a seat frame. However, 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 and to protect and strengthen from damage, a reinforcing fabric such as a nonwoven fabric is integrated as a backing material on the back of the pad body made of flexible foam by foam molding of the flexible foam. It has been done.

  FIG. 8 is a cross-sectional view of the sheet pad 100 provided with such a reinforcing cloth, which comprises a main portion 102 at the center in the width direction and side portions 104 formed in a bulging shape upward on the left and right sides. 104 is provided with a protruding portion 106 protruding to the back surface side. A reinforcing cloth 108 is laminated and integrated from the back surface side of the main portion 102 to the inner wall surface 106 a of the protruding portion 106 in the side portion 104.

  In the pad structure including the protrusion 106 on the back surface side of the pad edge as described above, the inner wall surface 106a of the protrusion is formed so that the edge 108a of the reinforcing cloth 108 is laminated and integrated with the inner wall surface 106a of the protrusion 106. A permanent magnet is disposed on the mold surface to be molded, a magnetic member is attached to the edge 108a of the reinforcing cloth, and the magnetic body member is magnetically attracted to the permanent magnet, whereby the edge 108a of the reinforcing cloth is attached to the mold. There is a known example along the surface (for example, Patent Document 1).

  However, in such a known example, since the magnetic member attached to the reinforcing cloth 108 is usually attached after the reinforcing cloth 108 is cut, a predetermined position of the reinforcing cloth 108 corresponding to the permanent magnet disposed on the mold surface is provided. It is difficult to accurately attach the magnetic member, and therefore, there is a problem that the following molding defects are likely to occur. That is, when the magnetic member is disposed at a position shifted from the predetermined position, when the reinforcing cloth 108 is attached to the upper mold surface, the edge 108a of the reinforcing cloth is aligned with the upper mold surface. In other words, wrinkles that spread outward as shown by a two-dot chain line X in FIG. 8 are generated. When the foaming stock solution is foam-filled with the reinforcing cloth 108 attached, there is a problem in that a molding failure may occur in which the flexible foam wraps around the back side of the reinforcing cloth 108 and the flexible foam is exposed on the back side. . In particular, when the magnetic member disposed on the reinforcing cloth 108 is a small magnetic metal member such as a staple of a stapler, for example, extremely high mounting position accuracy is required to prevent the occurrence of wrinkles as described above. Therefore, there is a problem that it is difficult to suppress the occurrence of molding defects due to the wrinkles as described above.

However, by providing a permanent allowance over a wide area of the mold surface and providing allowance, the generation of wrinkles as described above can be suppressed when the reinforcing cloth 108 is mounted, but the magnetic member is provided with a permanent magnet. Therefore, the magnetic member may be displaced due to the foaming pressure of the flexible foam at the time of foam molding, causing wrinkles on the reinforcing cloth, resulting in the above-described molding failure.
JP 2002-120236 A

  The present invention has been made in view of the above points, and solves the problem in the case where a magnetic member is disposed on the reinforcing cloth, so that the reinforcing cloth attached to the mold surface is free from wrinkles and has formability. An object of the present invention is to provide a method for producing a sheet pad excellent in the above.

  The sheet pad manufacturing method of the present invention is a sheet pad manufacturing method comprising: 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 flexible foam. The magnetic material member is disposed on the reinforcing cloth, and a first mold on which the reinforcing cloth is mounted and a second mold that forms a foaming space between the first mold and the first mold. Using a molding die in which a permanent magnet is disposed on the mold surface, the magnetic member is magnetically attracted to the permanent magnet, and the reinforcing cloth is attached to the mold surface of the first mold. Forming the pad body by foaming a foaming undiluted solution, and when the magnetic member is disposed on the reinforcing cloth, a punching hole is provided at a predetermined position of the reinforcing cloth, and the punching hole is marked The magnetic member on the reinforcing cloth Characterized in that it provided.

  In the present invention, the pad main body includes a protruding portion that protrudes to the back side at at least one edge of the peripheral portion, and the edge of the reinforcing cloth is laminated and integrated along the inner wall surface of the protruding portion. The magnetic member is disposed on an edge of the reinforcing cloth, and a recess is formed between the first mold and the second mold to form the protrusion, and the recess A permanent magnet may be disposed on the mold surface of the first mold that forms the inner wall surface of the first mold.

  In the sheet pad manufacturing method of the present invention, since the punched hole is provided at a predetermined position in the reinforcing cloth, the accurate position corresponding to the permanent magnet disposed on the mold surface with the punched hole as a mark. The magnetic member can be easily disposed. In addition, since the punching hole can be formed simultaneously with the die cutting process for forming the reinforcing cloth, the punching hole is always formed at an accurate position so that the magnetic member can be disposed at an accurate position. In addition, no additional work man-hours are required and the cost is not increased.

  Hereinafter, a vehicle seat pad according to an embodiment of the present invention will be described with reference to the drawings.

  1 and 2 are views showing a forming die 40 used when forming the sheet pad 10 according to the present embodiment, FIGS. 3 to 5 are views showing the sheet pad 10, and FIG. 6 is a reinforcing cloth. FIG.

  The seat pad 10 is a seat back pad that constitutes a backrest portion of a front seat of an automobile. As shown in FIGS. 3 to 5, a pad body 12 made of a highly elastic flexible polyurethane foam and laminated on the back surface thereof. And an integrated reinforcing cloth 30.

  The pad main body 12 includes a main portion 16 at the center in the width direction that receives the back of the occupant, and a pair of left and right side portions 18 and 18 that are formed in a raised shape on both sides in the width direction. Further, on the back surface side of the pad main body 12, an overhanging portion 20 formed in an inward flange shape at the upper edge portion of the main portion 16, and both rear edge portions of the side portion 18 and the lower edge portion of the pad main body 12 The protrusions 22, 22, and 23 are provided so that the inner wall surface 23 a of the protrusion 23 at the lower edge of the pad body 12 is connected to the back surface of the main part 16 by a gentle curved surface.

  The reinforcing cloth 30 is integrated by foam molding of polyurethane foam so as to cover substantially the entire back surface of the main portion 16 and a part of the inner wall surfaces 22a, 22a, 23a of the projecting portions 22, 22, 23, respectively. The inner side surface 20 a of the overhang portion 20 is also covered with the reinforcing cloth 30. Here, the reinforcing cloth 30 plays a role of protecting the pad body 12 or suppressing the generation of a rubbing sound with the seat frame. Non-woven fabrics, woven and knitted fabrics, and laminated composites of these can be used without particular limitation. For example, coarse blankets, cold chills, felts, and the like are used.

  The shape of the base fabric constituting the reinforcing fabric 30 is as shown in FIG. 6. The fabric main body portion 31 is integrated with the back surface of the main portion 16, and the side portion 18 is integrally extended from the left and right sides thereof. The cloth side edge portions 32, 32 integrated with the inner wall surface 22a of the protruding portions 22, 22 projecting on the back surface side, and the curved inner wall surface of the protruding portion 23 extending integrally from the lower side of the cloth main body portion 31. It consists of the cloth lower edge part 33 integrated with 23a. V-shaped cuts 34 are provided on the left and right sides of the upper portion of the cloth main body 31, and the opposite edges thereof are stitched together by a stitching portion 35. The cloth main body portion 31 is provided with a through hole 36 through which the mounting pin 58 is inserted when the reinforcing cloth 30 is locked to the mold surface of the core mold 48 attached to the upper mold 46. Further, the cloth side edge portion 32 and the cloth lower edge portion 33 are provided with punching holes 37 serving as marks when a magnetic member 38 to be described later is disposed.

  As shown in FIGS. 1 and 2, the molding die 40 for molding the sheet pad 10 includes a concave second mold (lower mold) 42 that is held substantially horizontally and molds the surface side of the pad main body 12, and a second mold 40. And a first mold 45 that opens and closes an upper surface opening of the mold 42 to form a cavity 44 that is a foaming space. The first mold 45 includes an upper mold 46 that is rotatably provided via a second mold 42 and a hinge 43, and a core mold 48 that is provided on the upper mold 46 so as to be vertically movable via a drive device 47. And has a shape corresponding to the back surface of the pad main body 12. Specifically, between the first mold 45 and the second mold 42 at the time of molding in which the first mold 45 closes the upper surface opening of the second mold 42, the projection 23 is molded on the hinge side. A concave portion 51 that is depressed upward is formed, a gap portion 49 for molding the protruding portion 20 is formed on the side opposite to the hinge, and a concave portion 50 that is depressed upward for molding the protruding portions 22 and 22 is formed on both left and right sides. Is formed.

  A permanent magnet 56 is disposed on the inner wall surface 50 a of the recess 50 formed in the first mold 45, that is, on the mold surface of the core mold 48 that molds the inner wall surface 22 a of the protrusion 22. The permanent magnet 56 is disposed on the inner wall surface 51 a of the recess 51 (that is, the mold surface of the core mold 48 that molds the curved inner wall surface 23 a of the protrusion 23), similarly to the inner wall surface 50 a of the recess 50. Has been. The permanent magnet 56 holds both edges 32 and 33 by magnetically attracting the magnetic members 38 disposed on the cloth side edge 32 and the cloth lower edge 33. Further, on the mold surface of the core mold 48 that molds the back surface of the main portion 16, a mounting pin 58 that is inserted into the through hole 36 provided in the cloth main body portion 31 projects from the cavity 44.

  In order to manufacture the sheet pad 10, first, a base fabric constituting the reinforcing fabric 30 is formed into a predetermined shape as shown in FIG. 6 by punching or the like. At that time, a circular punching hole 37 indicating the attachment position of the magnetic body member 38 at a predetermined portion of the cloth side edge portion 32 and the cloth lower edge portion 33 and a through hole through which the mounting pin 58 is inserted into a predetermined portion of the cloth main body portion 31. 36 is provided. In this embodiment, the punched hole 37 has a circular shape as shown in FIG. 7A, but is not limited to this. For example, the punched hole 37 has a square shape or a rectangular shape as shown in FIG. Various shapes such as a square shape, a triangular shape shown in FIG. 7C, or a cross-shaped cut shown in FIG. 7D can be adopted.

  A magnetic member 38 is disposed on the base fabric with the punched holes 37 provided in the cloth side edge portion 32 and the cloth lower edge portion 33 as marks, and a sewing portion 35 is formed by performing predetermined sewing. The magnetic member 38 disposed on the base cloth is not particularly limited as long as it can be satisfactorily magnetically attracted by being in contact with a magnet, but, for example, a soft iron stapler stop needle is suitable. . The magnetic member 38 is preferably fixed so that a part of the magnetic member 38 covers the punching hole 37, and more preferably, the stop needle is fixed so as to straddle the punching hole 37. By fixing the magnetic body member 38 in this way, it can be easily disposed on the base fabric while using the punching hole 37 as a mark.

  Next, the obtained reinforcing cloth 30 is placed on the mold surface of the core mold 48, and the mounting pin 58 projecting from the core mold 48 is inserted into the through hole 36 provided in the cloth main body portion 31, so that the cavity It is detachably attached to the first mold 45 side in 44. At that time, as shown in FIGS. 1 and 2, the magnetic member 38 disposed so as to straddle the punching hole 37 of the reinforcing cloth 30 is disposed on the inner wall surfaces 50 a and 51 a of the recesses 50 and 51. The cloth lower edge portion 33 and the cloth side edge portion 32 are fixed in a state in which the cloth lower edge portion 33 and the cloth side edge portion 32 are along the mold surface of the core die 48 by being brought into contact with 56 and magnetically attracted.

  Next, after injecting a polyurethane foam foaming stock solution U into the cavity 44 using an injector (not shown), the first mold 45 is closed to seal the cavity 44. Thereby, the foaming stock solution U is foam-filled in the cavity 44, the pad main body 12 made of polyurethane foam is molded, and the reinforcing cloth 30 is laminated and integrated on the back surface thereof.

  Then, after molding, the first mold 45 is opened, the core mold 48 is further detached from the upper mold 46 and the mold is opened, and the molded sheet pad 10 is removed from the core mold 48 to remove the mold. Specifically, by pulling the pad main body 12 to the front so as to be separated from the core mold 48, the mounting pin 58 is pulled out while the pad main body 12 made of polyurethane foam is bent with the protruding portion 20 as a fulcrum, and the side portion The magnetic attraction between the magnetic members 38 and the permanent magnets 56 at the protrusions 22, 22 provided on the back surface side of the protrusion 18 and the protrusion 23 at the lower edge of the pad main body 12 is released. In this state, the pad main body 12 is pushed upward so as to release the engagement between the projecting portion 20 and the core mold 48, so that the core pad 48 is removed, and the seat pad 10 is obtained. At that time, the cloth side edge portion 32 and the cloth lower edge portion 33 are locked by the magnetic attraction between the magnetic member 38 and the permanent magnet 56 without using the mounting pins, and therefore can be removed smoothly.

  In the manufacturing method of this embodiment, since the punching hole 37 that serves as a mark when the magnetic member 38 is provided is provided in the reinforcing cloth 30, the permanent die provided in the core mold 48 is used. The magnetic member 38 can be easily and accurately disposed at a predetermined position corresponding to the magnet 56. Therefore, when the reinforcing cloth 30 is attached to the core mold 48, the magnetic member 38 and the permanent magnet 56 are easily brought into contact with each other even at a position where it is difficult to perform a mounting operation such as a side surface or a lower surface of the core mold 48. It is excellent in workability, and the edges 32 and 33 of the reinforcing cloth 30 can follow the mold surface of the core mold 48 without being wrinkled. Generation | occurrence | production of the shaping | molding defect which goes around to the side and a polyurethane foam is exposed to the back side can be suppressed. Further, in the punching process of cutting the reinforcing cloth 30 into a predetermined shape, the punching hole 37 can be formed at the same time, so that the cost is not increased by providing the punching hole 37.

  In the above embodiment, the protrusions 22 and 22 provided on the back surfaces of the left and right side portions 18 and 18 and the protrusion 23 provided on the lower back edge of the main portion 16 are attached to the back surfaces thereof. Although the case where the molding defect caused by the cloth side edge portion 32 and the cloth lower edge portion 33 is eliminated has been described, it may be applied to only one of the side portion 18 and the lower edge portion of the main portion 16.

  In the above embodiment, the seat back pad used for the back portion of the automobile seat has been described. However, the seat back pad can be applied to a pad other than the back pad, for example, a seat cushion pad constituting a seat surface portion that receives the buttocks. It can also be applied to pads for sheets other than those for automobiles.

It is sectional drawing of the shaping | molding die at the time of manufacture of the pad for sheets which concerns on one Embodiment of this invention. It is a principal part enlarged view of the AA line cross section of FIG. It is the perspective view seen from diagonally back of the pad for the sheets. FIG. 4 is a sectional view taken along line BB in FIG. 3. It is CC sectional view taken on the line of FIG. It is a top view of the reinforcement cloth used for the pad for the sheet | seat. (A)-(d) is a figure which shows the shape of the punching hole provided in the reinforcement cloth. It is a partial expanded sectional view of the conventional seat pad.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Sheet pad 12 ... Pad main body 22, 23 ... Projection part 30 ... Reinforcement cloth 32 ... Fabric side edge part 33 ... Fabric lower edge part 37 ... Punching hole 38 ... Magnetic member 40 ... Mold 42 ... Second mold (lower mold) )
44 ... Cavity 45 ... First mold 46 ... Upper mold 48 ... Core mold 50, 51 ... Recess 50a, 51a ... Inner wall surface 56 ... Permanent magnet

Claims (2)

In a method for manufacturing a pad for a sheet comprising a pad body made of a flexible foam and a reinforcing cloth laminated and integrated by foam molding of the flexible foam on the back surface of the pad body,
A magnetic member is disposed on the reinforcing cloth,
A molding die comprising a first mold to which the reinforcing cloth is attached and a second mold that forms a foaming space between the first mold and a permanent magnet disposed on the mold surface of the first mold. make use of,
The magnetic body member is magnetically attracted to the permanent magnet, the reinforcing cloth is attached to the mold surface of the first mold, the foam body is foamed in the foaming space, and the pad body is molded,
When arranging the magnetic member on the reinforcing cloth, a punching hole is provided at a predetermined position of the reinforcing cloth, and the magnetic member is arranged on the reinforcing cloth with the punching hole as a mark. A method for manufacturing a pad for a sheet. The pad main body includes a protruding portion that protrudes toward the back surface at at least one edge of the peripheral edge, and the edge of the reinforcing cloth is laminated and integrated along the inner wall surface of the protruding portion. ,
Arranging the magnetic member on the edge of the reinforcing cloth;
A recess for forming the protrusion is formed between the first mold and the second mold, and a permanent magnet is disposed on the mold surface of the first mold that forms the inner wall surface of the recess. The manufacturing method of the pad for sheets of Claim 1 characterized by the above-mentioned.

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