JP2006346348A - Production method of seat pad for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production method of a seat pad for a vehicle which is excellent in a sitting feeling and a riding feeling and is light in weight. <P>SOLUTION: A vacant hole 6 communicating with the outside is extended in the seat pad 1. A core 10 is disposed to be laid between anchors 23 and 24. An upper mold 21 is put after the core 10 is set in a lower mold 22 and an urethane foam raw solution is supplied, and the seat pad 1 is molded by heating and foaming the solution after the mold is clamped. Then, the molds are opened and the seat pad 1 is removed from the molds. Consequently, the core 10 which remains in the seat pad 1 is dissolved in a solvent and is removed. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a vehicle seat pad.

  A vehicle seat pad (hereinafter sometimes simply referred to as a seat pad) is generally composed of a foamed material such as a flexible polyurethane foam or a semi-rigid polyurethane foam.

  Japanese Patent Application Laid-Open No. 11-34710 discloses a seating sensor in which a recess is provided that is recessed upward from the bottom surface of a seat pad, and a nest is inserted into the recess, and a sensor is installed on the top surface of the nest. With seats listed. This nesting is made of the same urethane foam as the seat pad (paragraph 0011 of the same publication).

  In the same publication, there are other objects embedded by opening holes, but the manufacturing method is not disclosed.

  In order to reduce the weight of the seat pad, it is conceivable to provide a recess that is recessed upward from the bottom surface of the seat pad and leave the recess hollow (that is, so-called “stealing meat”). If it does in this way, the rigidity of the bottom face vicinity of a seat pad will become low, and it will become easy to sense a feeling of bottom when sitting on a seat pad.

  In order to reduce the weight of the seat pad, it is conceivable to provide a groove on the seat pad's seating surface contrary to the above. Become so.

  Furthermore, a seat pad having an air conditioning function is known.

  For example, in Japanese Patent Publication No. 9-505499, an air flow path is provided in a cushion, and the air flow path communicates with a groove provided on a seat surface of the cushion. A seat pad covered by a chair upholstery layer is described. The temperature-controlled air flows out from the seating surface of the seat pad through the air flow path, the groove, and the chair upholstery layer.

However, since the seat pad disclosed in Japanese Patent Publication No. 9-505499 has a groove on the seat seating surface, a feeling of unevenness occurs when sitting on the seat pad. In order to prevent this unevenness, a thick slab urethane or skin is often used, but in that case, the cost becomes high.
JP 11-34710 A JP-T 9-505499

  An object of this invention is to provide the manufacturing method of the lightweight and air permeable vehicle seat pad excellent in sitting comfort and riding comfort.

  The method for manufacturing a vehicle seat pad according to claim 1 is a method for manufacturing a vehicle seat pad in which a hole communicating with the outside extends inside, wherein the core is disposed in a mold. The step of foam-molding the seat pad in the mold, the step of removing the seat pad having the core, and the step of dissolving and removing the core.

  The method for manufacturing a vehicle seat pad according to claim 2 is characterized in that, in claim 1, one end of the hole faces the seat surface of the vehicle seat pad, and the other end faces the bottom surface. It is.

  According to a third aspect of the present invention, there is provided a vehicle seat pad manufacturing method according to the second aspect, wherein the vicinity of the one end and the other end of the hole extends in the vertical direction, and the gap between the one end and the other end. Is a horizontal portion extending substantially in the horizontal direction.

  The method for manufacturing a vehicle seat pad according to claim 4 is characterized in that, in claim 3, anchor portions for forming the one end portion and the other end portion project from the upper surface and the lower surface of the inner surface of the mold, A foam molding step is performed by bridging a core between the anchor portions.

  According to a fifth aspect of the present invention, there is provided a vehicle seat pad manufacturing method according to the fourth aspect, wherein the mold includes an upper mold and a lower mold, and the upper end and the lower mold are formed with the one end and the other end. Anchor portions are respectively provided in a protruding manner, and a foam molding process is performed by bridging a core between the anchor portions.

  According to a sixth aspect of the present invention, there is provided a vehicle seat pad manufacturing method according to the fourth aspect, wherein the mold includes an upper mold and a lower mold, and a middle mold disposed between the upper mold and the lower mold. And the anchor part for forming the said one end part and other end part is each protrudingly provided in the lower mold | type, and a foam molding process is performed by spanning a core between these anchor parts It is.

  The method for manufacturing a vehicle seat pad according to claim 7 is characterized in that, in any one of claims 1 to 6, the core has a hollow portion extending in the extending direction of the hole. It is.

  The method for manufacturing a vehicle seat pad according to claim 8 is characterized in that, in any one of claims 1 to 7, the core is made of a resin soluble in a solvent.

  According to a ninth aspect of the present invention, there is provided the method for manufacturing a vehicle seat pad according to the eighth aspect, wherein the core is made of a resin foam.

  The method for manufacturing a vehicle seat pad according to claim 10 is characterized in that, in claim 8 or 9, the core contains particles insoluble in the solvent.

  The vehicle seat pad manufacturing method according to an eleventh aspect is characterized in that, in any one of the first to tenth aspects, the hole diameter is 1 to 50 mm.

  The vehicle seat pad manufacturing method according to claim 12 is characterized in that, in any one of claims 1 to 10, the volume of the holes is 1 to 10% of the volume of the vehicle seat pad. It is.

  Since the vehicle seat pad manufactured by the method of the present invention has holes, the weight can be reduced accordingly. Since this hole is provided in the seat pad, there is no foreign object feeling when sitting, and the feeling of bottoming is also prevented or suppressed because the rigidity reduction near the bottom surface is prevented. Since this vehicle seat pad has holes, it has an air conditioning function. Sensors and heaters can be inserted.

  As described in claim 11, by setting the hole diameter to 1 to 50 mm, the feeling of bottoming can be surely prevented. As described in claim 12, by setting the volume of the holes to 1 to 10%, it is possible to more reliably prevent the feeling of bottoming.

  As described in claim 2, when the end of the hole faces the seating surface of the seat pad, there is an advantage that air flows in and out from the bottom surface to the seating surface. In this case, if the end of the hole faces a plurality of locations on the seating surface, the hole is not covered by the occupant when sitting on the seat pad, and air is reliably released from the hole to the outside. To come in and out.

  When the end of the hole faces the bottom surface of the seat pad, there is an advantage that air can be fed from the bottom surface.

  As in claim 3, the vicinity of the one end and the vicinity of the other end of the hole extends in the vertical direction, and the portion between the one end and the other end is a horizontal portion extending in a substantially horizontal direction. In the case of the configuration, the cushion characteristics of the seat pad are equalized over a wide range.

  According to the method of Claims 4-6, since a core forms a horizontal direction part, the volume of a core becomes small compared with the case where all the void | holes are formed with a core. For this reason, the time for dissolving the core is shortened, the manufacture of the vehicle seat pad is facilitated, the consumption of the core and the solvent is reduced, and the manufacturing cost is reduced.

  According to the method of claim 7, dissolution of the core can be promoted. Further, since the volume of the core to be dissolved is reduced, the manufacture of the vehicle seat pad is facilitated, and the manufacturing cost is reduced.

  As described in claim 8, the core is preferably made of a resin soluble in a solvent. As described in claim 9, by using the core as a resin foam, the core is easily dissolved.

  As described in claim 10, by containing particles insoluble in the solvent in the resin constituting the core, the amount of resin to be dissolved by the solvent is reduced.

  Hereinafter, preferred embodiments of a vehicle seat pad and a manufacturing method thereof according to the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view showing an embodiment of a vehicle seat pad of the present invention, and FIG. 2 is a perspective view showing holes in the vehicle seat pad of FIG.

  The vehicle seat pad 1 includes a bottom part 2, a thigh part 3, and a side part 4.

This seat pad is made of polyurethane foam. When a slab urethane having a thickness of 5 mm or more or the like is used as a cover material on a seat pad for a vehicle that emphasizes cushioning or a seat pad, the core density is 25 to 25. A polyurethane foam having 70 kg / m ³ and 25% hardness of 15 to 25 kgf / φ200 is desirable.

On the other hand, in the case of a seat pad for which a soft feeling is desired on the surface or a seat pad aiming to improve the initial seating feeling, the constituent material of the seat pad is a core density of 30 to 70 kg / m ³ , 25% hardness of 8 to 8 A polyurethane foam of 20 kgf / φ200 is desirable.

  In this seat pad 1, a hole 6 communicating with the outside is extended. In this embodiment, the hole 6 includes a substantially horizontal horizontal portion 6b that extends in the front, rear, left, and right inside the seat pad 1, and a standing portion 6a that continues to the horizontal portion 6b and faces the bottom surface of the seat pad. And a plurality of raised portions 6c that continue to the horizontal portion 6b and face the seating surface of the seat pad. The upright portions 6c are provided so as to be distributed over a wide range of the seating surface.

  Thus, the vehicle seat pad 1 provided with the holes 6 is lighter by the amount provided with the holes 6. Further, since the air holes 6 are provided inside the seat pad 1 except for the open portions at the end portions, the feeling received from the seat surface when sitting is good, and the vicinity of the bottom surface of the seat pad 1 is also provided. High rigidity and no bottoming.

  In particular, in this embodiment, the holes are provided over a wide area below the seating surface, and the cushion characteristics of the seat pad are substantially uniform over a wide range from the bottom of the buttocks to the bottom of the thigh.

  In the vehicle seat pad 1, the horizontal portion 6b is preferably provided at a position that is 10 mm or more, particularly 20 mm or more deeper than the seat surface of the seat pad, and 10 mm or more than the bottom surface of the seat pad. In particular, it is preferably provided 20 mm or more above.

  The hole diameter (diameter) of the air holes 6 is preferably about 1 to 50 mm, particularly about 10 to 20 mm. The volume of the pores is preferably about 1 to 10%, particularly about 1.5 to 4% of the volume of the seat pad.

  An example of a method for forming holes in the seat pad will be described with reference to FIGS.

  This seat pad is formed by supplying a urethane stock solution into a mold and foam-molding. In the method shown in FIGS. 3 to 6, a core 10 made of a solvent-soluble resin is placed in the mold 20. Keep it. Holes 6 are formed by removing the molded body from the mold after foaming of urethane, and then dissolving and removing the core 10.

  The mold 20 includes an upper mold 21 and a lower mold 22. From the cavity surface of the upper die 21, a downwardly projecting anchor 23 is provided to form the upright portion 6a. From the bottom surface of the cavity of the lower die 22, a plurality of upwardly projecting anchors are formed. 24 is provided. The anchors 24 are provided in the same number as the upright portions 6c and in the same arrangement as the upright portions 6c.

  In molding, the core 10 is arranged so as to be bridged between the anchors 23 and 24 as shown in FIGS. After supplying the urethane foaming stock solution (not shown), the upper die 21 is put on, the mold is clamped as shown in FIG. 3, and then heated and foamed to form the seat pad 1 as shown in FIG. Thereafter, the mold is opened and the seat pad 1 is removed.

  FIG. 5 is a cross-sectional view of the seat pad 1 that has been removed from the mold, in which an upright portion 6a and an upright portion 6c are formed of traces of the anchors 23 and 24.

  Next, the core 10 remaining in the seat pad 1 is dissolved and removed with a solvent. Thereby, as shown in FIG. 6, the seat pad 1 in which the horizontal direction part 6b was formed is obtained.

  As resin which comprises the said core 10, foamed resin is more suitable than non-foamed resin. This is because the amount of resin to be dissolved in the same apparent volume is much smaller. Moreover, it is preferable that the shape of the core 10 is hollow rather than solid. FIG. 7 is a sectional view of the seat pad 1 in the middle of molding using the hollow core 10A. The hollow core 10A requires less resin to be dissolved by the amount of the internal cavity than the solid core 10.

When the core 10A is dissolved by supplying a solvent, an opening is opened in the core 10A facing the holes of the upper and lower portions 6c and 6a, and the core 10A is formed into a cylindrical shape. The core 10A can be quickly dissolved and removed by circulating the solvent.
In this way, instead of opening the opening, a cylindrical core (not shown) in which a portion facing the rising portion 6c and the falling portion 6a is opened from the beginning may be used. In this case, it is desirable to connect each opening to the anchors 23 and 24 in an airtight manner so that urethane foaming does not enter the core.

  As the resin material that constitutes the cores 10 and 10A, a material that is soluble in a solvent that does not attack the urethane that constitutes the seat pad is used. Examples of the solvent that does not attack urethane include methyl chloride, terpene oil, gasoline, limonene, and benzene, and limonene is particularly preferable. Examples of the resin soluble in limonene include styrene foam.

  Examples of the resin soluble in methyl chloride include expanded polystyrene, and examples of resins soluble in terpene oil, gasoline, and benzene include expanded polystyrene, PE (polyethylene) foam, and PP (polypropylene) foam.

  By including solvent-insoluble particles in such a resin, the amount of constituent resin to be dissolved in the solvent can be reduced. As these particles, particles of inorganic substances such as sand and glass beads are suitable, and sand having a particle size of about 0.01 to 0.1 mm and beads such as glass having a particle size of about 2 to 10 mm are particularly suitable.

  The above-described embodiment is an example of the present invention, and forms other than the illustration of the present invention can be taken. For example, as shown in FIG. 8, the air hole has a rising portion 31 facing the bottom surface of the seat pad, a substantially horizontal horizontal portion 32, and an upward gradient from the horizontal portion 32 in the radial direction toward the tip. Each of the radial direction portions 33 and a rising portion 34 that rises from the tip of each radial direction portion 33 and faces the seating surface of the seat pad. The pores may have other forms.

  In the said embodiment, although the metal mold | die consisting of an upper mold | type and a lower mold | type is used, the kind of metal mold | die is not limited to this. FIGS. 9 to 12 are cross-sectional views for explaining a method of manufacturing a vehicle seat pad using a mold composed of an upper mold, a lower mold, and a middle mold.

  As shown in FIG. 9, the mold 50 includes an upper mold 51, a lower mold 52, and a middle mold 53. A cylinder 60 is installed on the upper surface of the upper mold 51. A rod 61 is accommodated in the cylinder 60 so as to be slidable up and down. The lower end side of the rod 61 protrudes from the cylinder 60 and is inserted into a through hole 51 a provided through the upper mold 51. A middle mold 53 is provided at the lower end of the rod 61. The middle mold 53 can be brought into and out of contact with the upper mold 51 as the rod 61 moves up and down.

  From the lower surface in FIG. 9 of the middle mold 53, a downwardly projecting anchor 54 is provided to form the upright part 6a, and from the bottom surface of the cavity of the lower mold 22, a plurality of upwardly projected parts are formed. An anchor 55 is provided.

  At the time of molding, the core 10 is arranged so as to be bridged between the anchors 54 and 55. After supplying the urethane foaming stock solution (not shown), the lower mold 52 is covered with the upper mold 51 and the middle mold 53, set in the mold-clamped state of FIG. 9, and then heated and foamed to form the seat pad 1A.

  Thereafter, as shown in FIGS. 10 and 11, the mold is opened, and the upper mold 51, the middle mold 53, and the seat pad 1A are removed from the lower mold 52. Next, the rod 61 is moved downward to separate the middle mold 53 from the upper mold 51, and the seat pad 1A is removed.

  As shown in FIG. 12, the seat pad 1A is formed with a raised portion 6a and a raised portion 6c made of traces of the anchors 54 and 55.

  Next, the core 10 remaining in the seat pad 1A is dissolved and removed with a solvent. Thereby, the seat pad 1A in which the horizontal portion 6b is formed is obtained.

It is a perspective view which shows the vehicle seat pad manufactured by the method which concerns on embodiment of this invention. It is a perspective view of the hole of the vehicle seat pad of FIG. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on another embodiment. It is a perspective view of the hole of the vehicular seat pad concerning another embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on different embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on different embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on different embodiment. It is sectional drawing which shows the manufacturing method of the vehicle seat pad which concerns on different embodiment.

Explanation of symbols

1,1A Seat pad 6,30 Hole 10,10A Core 20,50 Mold 23,24,54,55 Anchor part

Claims (12)

A method of manufacturing a vehicle seat pad having holes,
Placing the core in the mold;
Foam molding a seat pad in the mold;
Removing the seat pad having the core;
And a step of dissolving and removing the core.   2. The method of manufacturing a vehicle seat pad according to claim 1, wherein one end portion of the hole faces the seat surface of the vehicle seat pad and the other end portion faces the bottom surface.   3. The horizontal direction portion according to claim 2, wherein the vicinity of the one end portion and the other end portion of the hole extends in a vertical direction, and the portion between the one end portion and the other end portion extends in a substantially horizontal direction. A method for manufacturing a vehicle seat pad. In claim 3, anchor portions for forming the one end portion and the other end portion are respectively provided on the upper surface and the lower surface of the inner surface of the mold,
A method of manufacturing a vehicle seat pad, wherein a foam molding step is performed by bridging a core between the anchor portions. In claim 4, the mold comprises an upper mold and a lower mold,
Anchor portions for forming the one end portion and the other end portion project from the upper die and the lower die, respectively.
A method of manufacturing a vehicle seat pad, wherein a foam molding step is performed by bridging a core between the anchor portions. In claim 4, the mold comprises an upper mold, a lower mold, and a middle mold disposed between the upper mold and the lower mold,
Anchor portions for forming the one end portion and the other end portion project from the middle mold and the lower mold, respectively.
A method of manufacturing a vehicle seat pad, wherein a foam molding step is performed by bridging a core between the anchor portions.   The method for manufacturing a vehicle seat pad according to any one of claims 1 to 6, wherein the core has a hollow portion extending in a direction in which the air holes extend.   The method for manufacturing a vehicle seat pad according to any one of claims 1 to 7, wherein the core is made of a resin soluble in a solvent.   9. The method of manufacturing a vehicle seat pad according to claim 8, wherein the core is made of a resin foam.   The method for manufacturing a vehicle seat pad according to claim 8 or 9, wherein the core contains particles insoluble in the solvent.   The method for manufacturing a vehicle seat pad according to any one of claims 1 to 10, wherein the hole has a hole diameter of 1 to 50 mm.   The method for manufacturing a vehicle seat pad according to any one of claims 1 to 10, wherein the volume of the holes is 1 to 10% of the volume of the vehicle seat pad.

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