JP2007106240A - Seat pad for vehicle and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To suitably provide a seating sensor in a seat pad integrally formed by foaming a polyurethane material on a film layer formed by a polyurethane elastomer material. <P>SOLUTION: This seat pad is made by laminating different kinds of polyurethane resin. The seat pad has the first film layer 10 formed by the polyurethane elastomer material and mold foam 30 in which the polyurethane foam material is foamed and formed and is integrally adhered on the formed first film layer 10. The sheet-like seating sensor S for detecting seating of an occupant is arranged in a laminated state between the first film layer 10 and the mold foam 30. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a vehicle seat pad and a method for manufacturing the same. More specifically, the present invention relates to a vehicle seat pad that can suitably maintain the resilience, hardness, and the like of a vehicle seat pad configured by integrating different types of polyurethane resins.

Conventionally, as a cushion structure of a backrest part (seat back) and a seating part (seat cushion) of a vehicle seat, for example, a so-called mold foam obtained by foaming a polyurethane resin raw material is covered with a fabric skin cover, Known is one in which a skin made of vinyl chloride is integrally molded under reduced pressure. As this type of related technology, the technology disclosed in Patent Document 1 can be cited.
JP 2000-311564 A

However, the above-described cushion structure has been pointed out as a problem because, for example, the use of vinyl chloride itself has a large influence on the environment, or it has been pointed out that it is difficult to improve cushioning and design properties, and technical problems have been pointed out. .
In order to solve the above-mentioned problems, the present inventor previously molded a polyurethane foam raw material on a film layer (skin cover) formed of a polyurethane elastomer raw material, and integrally molded them to form a seat pad. Has been proposed (Japanese Patent Application No. 2004-188252, not known at the time of this application). According to this proposed technology, the seat pad can be formed using only a polyurethane resin having a small influence on the environment, and the cushioning property that is synergistically exhibited with the tension of the skin cover and the mold foam is suitable. To be able to adjust.
By the way, a so-called seating sensor is disposed in a vehicle seat in recent years in order to detect the presence or absence of seating on the seat (see, for example, Patent Document 1). This seating sensor is usually installed between the skin cover and the pad of the seat cushion so that the detection can be satisfactorily performed even in cold weather. In the case of the above-mentioned Patent Document 1, the seating sensor is attached to the seating surface side of the pad by an adhesive means such as a double-sided tape at the position.
Therefore, also in the technology for forming the seat pad previously proposed by the present inventor, a cushion structure provided with a seating sensor is required from the viewpoint of putting the proposed technology into practical use.

  Thus, the problem to be solved by the present invention is to suitably provide a seating sensor even in the case of a vehicle seat pad in which different types of polyurethane resins previously proposed by the present inventor are laminated. is there.

In order to solve the above problems, the vehicle seat pad and the manufacturing method thereof according to the present invention take the following means.
First, the first invention is a vehicle seat pad having a structure in which different types of polyurethane resins are laminated, on a first film layer formed of a polyurethane elastomer raw material, and on the formed first film layer A polyurethane foam raw material is foam-molded and integrally bonded, and a planar seating sensor for detecting the seating of an occupant is disposed between the first film layer and the mold foam in a laminated manner. It has been established.
Here, as the seating sensor, for example, a planar sensor formed with flexibility that does not impair the seating feeling like a membrane switch can be cited.
According to the first aspect of the present invention, the adhesion site between the first film layer and the mold foam integrally molded thereon is not easily impregnated with the interface and is hard to be cured. In addition, since the first coating layer and the mold foam are integrally formed, the seating sensor disposed at a position therebetween is stably held at the disposed position. That is, by placing the seating sensor at the position where the seating sensor is to be disposed, it can be adhered with the adhesive strength exhibited by the molding of the first film layer or the mold foam, and is manually attached separately. Work is omitted. In addition, the first film layer formed from the polyurethane elastomer raw material hardly shrinks even if the temperature is lowered to the use environment after molding. Therefore, it is possible to stably exert the sensor function without applying a load accompanying the contraction deformation to the seating sensor.

Next, according to a second aspect of the present invention, in the first aspect described above, a planar seating sensor for detecting the seating of an occupant and a seating load of the occupant are supported between the first coating layer and the mold foam. The insert member formed with a desired hardness corresponding to the supporting portion to be disposed is disposed in a laminated manner, and the disposition positional relationship between the planar seating sensor and the insert member is a planar seating sensor. Is the first film layer side.
Here, examples of the “supporting part that supports the seating load of the occupant” include a part that supports the thigh, the lower buttocks, the waist, and the vicinity of the scapula of the occupant. Since the magnitude | size of the input vibration and the magnitude | size of this load differ depending on the support site | part, such a site | part preferably adjusts cushioning property according to each support site | part.
According to the second aspect of the invention, the insert member whose hardness is appropriately adjusted according to the support portion that supports the seating load of the occupant is stably held together with the seating sensor at the disposed position. By installing the insert member, the cushioning property of the seat pad can be more suitably adjusted according to the support portion that supports the occupant. Even if the insert member is installed, a stable sensor function is exhibited by the seating sensor installed on the first film layer side.

Next, according to a third invention, in the first or second invention described above, a polyurethane elastomer raw material is further molded between the mold foam and the seating sensor or the insert member disposed facing the mold foam. A second coating layer is deposited.
According to the third aspect of the invention, the seating sensor or the insert member disposed facing the mold foam is bonded with the adhesive strength between the first film layer and the second film layer. Hold status is improved. Moreover, since impregnation is not accompanied between the seating sensor and the mold foam, the cushion function and the sensor function are not impaired.

Next, according to a fourth aspect of the present invention, in any one of the first to third aspects described above, the different types of polyurethane resins have different hardnesses.
According to the fourth aspect of the invention, polyurethane resins having different hardnesses are laminated, and the cushioning property of the seat pad can be adjusted in a wider range by the combination.

Next, according to a fifth invention, in any one of the first to fourth inventions described above, the first coating layer formed in the lowermost layer is configured as a skin of a vehicle seat.
According to the fifth aspect of the invention, the use of the first film layer as the skin eliminates the need for a separate skin covering operation. The first film layer that becomes the skin is less likely to cause defects such as wrinkles and air accumulation during molding. For example, by transferring a wrinkle shape set in a mold, it is finished in a good installation state and design surface. It is possible.

Next, a sixth invention is a method of manufacturing a vehicle seat pad having a structure in which different types of polyurethane resins are laminated, and the first film layer is formed by spraying or applying a polyurethane elastomer raw material in a mold. A first coating layer forming step, a sensor installation step of installing a planar seating sensor for detecting the seating of an occupant on the first coating layer, and a first coating layer on which the seating sensor is installed And a foam forming step of foaming the mold foam by injecting a polyurethane foam raw material and integrally bonding with the first film layer and the seating sensor.
Here, as the seating sensor, for example, a planar sensor formed with flexibility that does not impair the seating feeling like a membrane switch can be cited.
According to the sixth aspect of the invention, the first film layer is formed by the first film layer forming step. And a planar seating sensor is installed in a laminated form on the first film layer by the sensor installation process. Furthermore, the polyurethane foam raw material is injected onto the first film layer on which the seating sensor is installed by the mold foam molding process, and the mold foam is integrally foam-molded. The adhesion site between the first film layer and the mold foam is difficult to be impregnated with the interface and hard to be cured. In addition, since the first coating layer and the mold foam are integrally formed, the seating sensor disposed at a position therebetween is stably held at the disposed position. In other words, by placing the seating sensor at the position where it should be placed, it can be bonded with the adhesive strength exhibited by the molding of the first film layer and the mold foam, and the work is affixed separately by hand. Is omitted. In addition, the first film layer formed from the polyurethane elastomer raw material hardly shrinks even if the temperature is lowered to the use environment after molding. Therefore, it is possible to stably exert the sensor function without applying a load accompanying the contraction deformation to the seating sensor.

Next, according to a seventh aspect, in the sixth aspect, the support for supporting the seating load of the occupant on the seating sensor installed on the first film layer by the sensor installation step after the sensor installation step. It has an insert member installation process which installs the insert member formed with the desired hardness according to a site | part.
Here, examples of the “supporting part that supports the seating load of the occupant” include a part that supports the thigh, the lower buttocks, the waist, and the vicinity of the scapula of the occupant. Since the magnitude | size of the input vibration and the magnitude | size of this load differ depending on the support site | part, such a site | part preferably adjusts cushioning property according to each support site | part.
According to the seventh aspect, the insert member is installed on the seating sensor installed on the first film layer by the insert member installation step. Then, in the second film layer forming step, the second film layer is formed on the first film layer on which the insert member and the seating sensor are installed. As a result, the insert member whose hardness is appropriately adjusted according to the support site for supporting the seating load of the occupant is stably held together with the seating sensor at the position where it is disposed. By installing this insert member, the cushioning property of the seat pad can be more suitably adjusted according to the support portion that supports the seating load of the occupant. Even if the insert member is installed, a stable sensor function is exhibited by the seating sensor installed on the first film layer side.

Next, an eighth invention is the above-described sixth or seventh invention, wherein the seating sensor or the seating sensor and the insert member are installed on the first coating layer after the sensor installation step or the insert member installation step. And a second coating layer forming step of forming a second coating layer by spraying or coating a polyurethane elastomer raw material.
According to the eighth aspect, the second coating layer is formed on the first coating layer on which the seating sensor or the insert member is installed by the second coating layer forming step. Therefore, since the seating sensor insert member is bonded with the adhesive strength between the first film layer and the second film layer, these hold states are improved. Moreover, since impregnation is not accompanied between the seating sensor and the mold foam, the cushion function and the sensor function are not impaired.

The present invention can obtain the following effects by taking the above-described means.
First, according to the first invention, a seating sensor can be suitably installed on a seat pad formed by stacking different types of polyurethane resins. That is, for example, in the case of a configuration in which the seating sensor is attached to the seating surface side of the pad by an adhesive means such as a double-sided tape, the seating sensor is difficult to adhere due to the release agent attached to the seating side surface of the pad. Work is time consuming. However, according to the present invention, the seating sensor can be easily bonded by installing the seating sensor when the first coating layer or the mold foam is molded, and with the adhesive strength exhibited by these moldings. The seating sensor can be held stably. In addition, since the first coating layer hardly contracts even if the temperature is lowered to the usage environment after molding, the sensor function of the seating sensor can be stably exhibited.
Furthermore, according to 2nd invention, the cushioning property of a seat pad can be adjusted more suitably according to the support site | part which supports a passenger | crew by installation of an insert member. And this insert member can be hold | maintained stably with a seating sensor.
Furthermore, according to the third aspect, the seating sensor can be held more stably. In addition, it is possible to more suitably adjust the cushioning properties of the support portions that support the occupant seated on the seat.
Furthermore, according to the fourth invention, the cushioning property of the seat pad can be adjusted in a wider range by the combination of polyurethane resins having different hardnesses.
Furthermore, according to the fifth aspect, the operation of covering the seat pad with the skin can be rationalized, and the skin can be finished in a good installation state and design surface.
Further, according to the sixth invention, the seating sensor can be suitably installed on the seat pad formed by stacking different types of polyurethane resins by a simple manufacturing method. That is, for example, in the case of a configuration in which the seating sensor is attached to the seating surface side of the pad by an adhesive means such as a double-sided tape, the seating sensor is difficult to adhere due to the release agent attached to the seating side surface of the pad. Work is time consuming. However, according to the present invention, the seating sensor can be easily bonded by the method of installing the seating sensor on the molded first film layer and integrally molding the mold foam on the seating sensor. The seating sensor can be stably held with the adhesive strength exhibited by the molding. In addition, since the first film layer to which the seating sensor is bonded does not easily shrink even if the temperature is lowered to the use environment after molding, the sensor function of the seating sensor can be stably exhibited.
Furthermore, according to the seventh aspect, the insert member and the seating sensor can be stably held by a simple manufacturing method. And by installation of this insert member, the cushioning property of a seat pad can be adjusted more suitably according to the support site | part which supports a passenger | crew.
Furthermore, according to the eighth aspect, the seating sensor can be held more stably by a simple manufacturing method. In addition, it is possible to more suitably adjust the cushioning properties of the support portions that support the occupant seated on the seat.

  Embodiments of the best mode for carrying out the present invention will be described below with reference to the drawings.

  First, the vehicle seat pad 1 according to the first embodiment will be described with reference to FIGS. 1 is a cross-sectional view showing a schematic configuration of the seat pad 1 in a side view, FIG. 2 is a plan view showing the schematic configuration of the seat pad 1, FIG. 3 is a process diagram showing a first film layer forming step, and FIG. Is a process diagram showing a sensor installation process and an insert member installation process, FIG. 5 is a process chart showing a second film layer molding process, FIG. 6 is a process chart showing a mold foam molding process, and FIG. 7 is a foam molding in the mold foam molding process. It is process drawing which shows a state. Note that the seat pad 1 shown in FIG. 1 is shown in a state where the seat pad 1 is turned upside down with respect to the assembly posture state of the seat.

The seat pad 1 of this embodiment is applied to a seating portion (seat cushion) of a vehicle used outdoors such as a forklift. As shown in FIG. 1, the seat pad 1 has a thermosetting aliphatic polyurethane elastomer raw material formed on the surface side (sitting surface side) of a mold foam 30 formed by foaming a flexible polyurethane foam raw material. The first film layer 10 is integrally bonded. Here, the flexible polyurethane foam raw material is mainly composed of a polyol (manufactured by Mitsui Takeda Chemical Co., MHR-2289) and a mixture of tolylene diisocyanate and methylene diisocyanate isocyanate (manufactured by Mitsui Takeda Chemical Co., Cosmonate TM20). A known mixed solution obtained by reacting other foaming agent, foam stabilizer, catalyst, colorant and the like is used.
In the present embodiment, the first skin layer 10 formed as described above forms a skin surface that supports the seating load of the occupant in direct contact. Here, the skin surface is given a textured shape at the time of molding in order to improve the design. Further, the seat pad 1 includes a seating sensor S for detecting the presence or absence of seating on the seat between the first coating layer 10 serving as the epidermis and the mold foam 30 serving as the pad portion. An insert member T for adjusting the cushioning property is integrally incorporated.

  As shown in FIG. 2, the former seating sensor S is formed in a substantially U shape so as to be in contact with the vicinity of the bottom of the bottom where it is easy to detect the seating of the occupant. This seating sensor S is constituted by a known membrane switch as it can constitute a system at a relatively low cost. Here, the schematic configuration of the membrane switch will be described. The membrane switch is formed into a planar shape obtained by polymerizing a pair of flexible sheets via an insulating spacer. According to the seating sensor S constituted by this membrane switch, it is possible to detect the load applied in the planar thickness direction.

The latter insert member T is formed of foamed slab foam (density: 20 kg / m ³ , hardness: 100 N, thickness: 10 mm), and as shown in FIG. It is installed to be. Therefore, the cushioning feeling, tactile feeling (surface tactile feeling), bottomed feeling and stability feeling of the seat pad 1 can be adjusted over a wide range according to the material characteristics (viscoelasticity and hardness) of the inserted insert member T. The material of the insert member T is preferably a material having excellent recyclability such as foamed slab foam (foamed urethane material), but other known rubber materials (rubber elastomers) and olefins are also used. A member made of a resin material or the like can be used. Moreover, you may use what combined these materials. Further, the part where the insert member T is installed is not limited to the part that hits the lower buttocks of the occupant, and may be installed in another part such as the vicinity of the thigh. Further, when the seat pad is applied to the backrest (seat back), an insert member may be installed at a portion that is in contact with the occupant's waist or the vicinity of the scapula. In this case, as the insert member T, a member having material characteristics (viscoelasticity or hardness) suitable for the part to be installed is appropriately selected and used. In the present embodiment, referring to FIG. 1, since the first coating layer 10 serving as the skin and the mold foam 30 serving as the pad have different hardnesses, a combination of these thickness dimensions, etc. The cushioning property of the seat pad 1 can also be adjusted by changing the alignment.

Next, a method for manufacturing the seat pad 1 will be described in the order of steps shown in FIGS. 3 to 7. In the following description, when referring to the seat pad 1, FIG.
First, as well shown in FIG. 3, the lower die 41 for molding the front surface side (sitting surface side) of the seat pad 1 is heated to 65 ± 4 ° C. and kept warm. Here, since the molding surface 41a of the lower mold 41 is a part surface that directly forms the design surface (sitting surface) of the seat pad 1, it may have a configuration in which a textured shape is imparted to the molding surface 41a. Thereby, the embossed shape set on the molding surface 41a can be transferred to the front surface side (sitting surface side) of the seat pad 1. In addition, it is preferable to apply a release agent to the molding surface 41a of the lower mold 41 in advance.
Next, as well shown in FIG. 3, the thermosetting aliphatic polyurethane elastomer raw material is spray-applied toward the molding surface 41 a of the lower mold 41 by the spray nozzle 50, and is left to heat for 60 seconds to be cured. Thereby, as FIG. 4 shows well, the 1st film layer 10 is shape | molded (1st film layer shaping | molding process).
Next, as well shown in FIG. 4, a planar seating sensor S is installed on the first film layer 10 in a stacked manner (sensor installation process). Further, on the seating sensor S, more specifically, the insert member T is installed in a layered shape at a portion that is brought into contact with the lower part of the occupant's bottom (insert member installation step). The seating sensor S and the insert member T may be installed after the first coating layer 10 is cured, but may be installed before curing. Thereby, for example, as the first coating layer 10 is cured, the first coating layer 10 and the seating sensor S or the insert member T can be integrally bonded by the adhesive strength accompanying the molding.

Next, as well shown in FIG. 5, the thermosetting aliphatic polyurethane elastomer raw material is applied to the first coating layer 10 by the spray nozzle 50 in the same manner as the first coating layer forming step (see FIG. 4) described above. It is spray coated over the entire surface, and is left to stand for 60 seconds for curing, for example. Thereby, as well shown in FIG. 6, the second coating layer 20 is deposited and molded in a state of being integrally bonded to the first coating layer 10, the seating sensor S, and the insert member T (second coating layer). Layer forming step).
Next, as shown well in FIG. 6, the flexible polyurethane foam raw material made of the above-mentioned mixed liquid is injected onto the previously formed second coating layer 20 by the injection nozzle 51, and the upper mold 42 is immediately closed. (See FIG. 7). Then, the mold 40 is left to heat for 6 minutes at the aforementioned temperature (65 ± 4 ° C.). As a result, the flexible polyurethane foam raw material foams and fills the space formed between the lower mold 41 and the upper mold 42. And the mold foam 30 is shape | molded in the form which adheres to the back surface of the 2nd membrane | film | coat layer 20 integrally with foaming (mold foam formation process). At the time of foam molding of the mold foam 30, the first film layer 10 and the second film layer 20 made of a flexible polyurethane foam raw material have good shape following properties, so that they are lifted or wrinkled from the molding surface 41 a of the lower mold 41. There will be no inconvenience. Therefore, the seat pad 1 is satisfactorily finished in a shape sandwiched between the molding surface 42 a of the upper mold 42 and the molding surface 41 a of the lower mold 41. Further, since the flexible polyurethane foam raw material is foam-molded and integrally bonded to the second film layer 20 formed of the polyurethane elastomer raw material, it is difficult to impregnate the interface that becomes the adhesion site during the foam molding. Therefore, the interface that becomes the adhesion site after molding is not locally cured.
Then, after the mold form 30 is formed, the upper mold 42 is released, and the integrally formed seat pad 1 is taken out from the mold 40, and the operation is completed. Therefore, in order to release the seat pad 1 smoothly, it is preferable to apply a release agent to the molding surface 42a of the upper mold 42 in advance.
In addition, the wire harness W connected to the seating sensor S can be released out of the mold from the relief groove 42b formed in the fitting shape of the lower mold 41 and the upper mold 42 of the mold 40. Accordingly, when the seat pad 1 is molded, for example, the second coating layer 20 or the mold foam is formed by performing each process in a state where the wire harness W is hung between the installation position of the seating sensor S and the escape groove 42b. As 30 is formed, the wiring position of the wire harness W can be fixed.

Next, the practicality of the seat pad 1 formed as described above was evaluated. The evaluation results are shown in Table 1. In this evaluation test, as shown well in Table 1, the sensor installation cost, sensor durability, sensor detection test (normal temperature /-) for the comparative products (a) to (c) and the invention products (d) to (f). 40 ° C.). And the evaluation result obtained by this evaluation test was shown in three steps using ○ △ ×. In the table, the results indicated by ◯ are good, the results indicated by △ are slightly inferior, and the results indicated by × are inferior. Here, the sensor detection test is to measure the load detected by the seating sensor S when a 50 kg load is applied to the seat top plate portion (sitting surface) by the iron grinder. For example, if this detected load is within a range of 2 to 20 kg, the evaluation result is ◯.
Here, the comparative product (a) has a structure in which a skin having a thickness of 5.5 mm made of a general jersey (with a lami pad) is placed on a mold foam (pad) obtained by foaming a flexible polyurethane foam raw material. . This comparative product (a) has a configuration in which a seating sensor is pasted on the seating surface side of the pad with a double-sided tape before the pad is covered with a skin (thin pasting). Here, the seating sensor is configured by the same planar membrane switch as the seating sensor S described above.
Next, the comparative product (b) has a structure in which a molded foam (pad) is integrally bonded to a 1.8 mm thick skin made of vinyl chloride (PVC) by integrally foaming a flexible polyurethane foam raw material. belongs to. In this comparative product (b), a seating sensor of an on / off switch type is provided at the lower position of the pad (lower position of the seat cushion) in response to the seating load of the occupant (ON / OFF switch). ).
Next, the comparative product (c) is obtained by subjecting a soft polyurethane foam raw material to foam molding integrally with a 1.8 mm-thick skin made of the same vinyl chloride (PVC) as the comparative product (b). ) Are integrally bonded. In this comparative product (c), the seating sensor constituted by the same planar membrane switch as in the comparative product (a) is installed in a state of being integrally bonded between the skin and the pad (thin pasting). . That is, the comparative product (c) is bonded with the adhesive strength exhibited by the molding of the mold foam by foam molding of the mold foam in a state where the seating sensor is installed on the skin.
On the other hand, the inventive products (d) to (f) are all formed by the above-described method for manufacturing the seat pad 1, but the polyurethane elastomer raw material comprising the first coating layer 10 and the second coating layer 20 is used. The thicknesses of the layers formed by the invention are different from the invention (d): 0.8 mm, the invention (e): 1.2 mm, and the invention (f): 1.8.
In addition, the structure of the mold foam 30 is a comparison product (a)-(c) and invention product (d)-(f), and all are common as density: 62kg / m < ³ > and rebound resilience: 76%. .

According to this evaluation result, in each evaluation item, a better result was obtained for the inventive product than for the comparative product.
For example, looking at the sensor installation cost, in the case of a configuration in which the seating sensor is affixed with a double-sided tape as in the comparative product (a), such affixing operation is time-consuming. Further, when the seating sensor of the ON / OFF switch is used as in the comparative product (b), the cost of the device itself increases. In contrast, in the inventions (d) to (f), the seating sensor S, which is relatively inexpensive, can be easily bonded by the manufacturing method described above.
Next, looking at sensor durability, in the case of a configuration in which the seating sensor is attached with double-sided tape as in the comparative product (a), the seating sensor is difficult to stick due to the release agent attached to the seating side surface of the pad. Become. Further, in the case of the structure in which the flexible polyurethane foam raw material is integrally foamed and molded on the skin made of vinyl chloride as in the comparative product (b) and the comparative product (c), the skin shrinks as the temperature decreases after molding. It becomes easy. In addition, in the configuration in which the seating sensor is exposed as in the comparative product (b), it is easily affected by the load accompanying the climate change in the cold time. Due to these factors, the durability of the seating sensor is not sufficiently exhibited. In contrast, in the inventions (d) to (f), the seating sensor S can be stably held by the above-described manufacturing method with the adhesive strength exhibited by the molding of each layer. Further, since the first film layer 10 and the second film layer 20 to which the seating sensor S is bonded are not easily contracted even if the temperature is lowered to the use environment after molding, the durability of the seating sensor S is sufficiently exhibited. .
Moreover, also in the sensor detection test (normal temperature and −40 ° C.), good results could be obtained with the inventive products (d) to (f) due to the same factors as described above.

Thus, the seat pad 1 of the present embodiment can be suitably installed with the seating sensor S on the seat pad 1 formed by stacking different types of polyurethane resins by a simple manufacturing method. That is, the seating sensor S can be easily bonded by a method in which the seating sensor S is installed on the molded first film layer 10 and the second film layer 20 and the mold form 30 are integrally formed thereon. In addition, the seating sensor S can be stably held with the adhesive strength exhibited by these moldings. Further, since the first film layer 10 and the second film layer 20 to which the seating sensor S is bonded are not easily contracted even if the temperature is lowered to the use environment after molding, the sensor function of the seating sensor S is stably exhibited. be able to. Adhesion of the seating sensor S does not require an adhesive that discharges a volatile organic compound (VOC), and therefore has little influence on the environment.
Furthermore, the insert member T and the seating sensor S can be stably held by a simple manufacturing method as in this embodiment. And by installation of this insert member T, the cushioning property of the seat pad 1 can be adjusted more suitably according to the support site | part which supports a passenger | crew's seating load. Furthermore, by using the first coating layer 10 as a skin, it is possible to rationalize the work of covering the seat pad 1 with the skin, and to finish the skin into a good installation state and design surface.

Although the embodiment of the present invention has been described with one embodiment, the present invention can be implemented in various forms in addition to the above-described embodiment.
For example, while the seat pad 1 uses the first coating layer 10 integrally bonded to the mold foam 30 as the skin, the seat pad 1 may be configured to cover another skin.
Further, the seat pad having the configuration shown in the above embodiment may be applied to a seat back as a backrest portion. In this case, the cushioning property of the seat pad can be suitably adjusted by, for example, installing an insert member at a part that is in contact with the occupant's waist or the vicinity of the scapula.
Moreover, although the thermosetting aliphatic polyurethane elastomer raw material is shown as the raw material for the first film layer and the second film layer, it may be a room temperature curable material or an aromatic material. However, in the case of use requiring weather resistance, it is preferable to use an aliphatic one because an aromatic one tends to yellow.
Further, the second coating layer does not need to be formed on the entire surface of the first coating layer, and it is sufficient that the second coating layer is formed so as to cover at least a portion where the seating sensor and the insert member are installed. Moreover, the structure which does not provide the 2nd membrane | film | coat layer, ie, the structure by which the seating sensor and insert member installed on the 1st membrane | film | coat layer are adhere | attached with a mold foam may be sufficient. In this case, it should be noted that the cushioning property of the mold foam may deteriorate the holdability of the seating sensor and the insert member. In addition, care must be taken because the insert member and the mold foam may be cured with impregnation during molding.
Further, the insert member is not necessarily required, and may be appropriately set according to the required performance of the seat pad. In the case of such a configuration in which the insert member is not installed, in the seat pad manufacturing method shown in the above embodiment, the insert pad installing step is omitted and the seat pad is formed (see FIG. 8).

It is sectional drawing which represented the schematic structure of the seat pad by side view. It is a top view showing a schematic structure of a seat pad. It is process drawing which shows a 1st film layer forming process. It is process drawing which shows a sensor installation process and an insert member installation process. It is process drawing which shows a 2nd film layer shaping | molding process. It is process drawing which shows a mold form formation process. It is process drawing which shows the foaming molding state in a mold form formation process. It is process drawing showing the manufacturing method of the seat pad of another Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Seat pad 10 1st membrane | film | coat layer 20 2nd membrane | film | coat layer 30 Mold form 40 Mold 41 Lower mold 41a Molding surface 42 Upper mold 42a Molding surface 42b Relief groove 50 Spray nozzle 51 Injection nozzle T Insert member S Seating sensor W Wire Harness

Claims (8)

A vehicle seat pad having a configuration in which different types of polyurethane resins are laminated,
A first film layer in which a polyurethane elastomer raw material is molded, and a mold foam in which the polyurethane foam raw material is foam-molded and integrally bonded onto the molded first film layer,
A vehicular seat pad in which a sheet-like seating sensor for detecting seating of an occupant is disposed between the first coating layer and the mold foam. The vehicle seat pad according to claim 1,
Between the first coating layer and the mold foam, a sheet-like seating sensor that detects the seating of the occupant and a desired hardness corresponding to the support site that supports the seating load of the occupant are formed. The insert member is arranged in a laminated form, and the arrangement positional relationship between the planar seating sensor and the insert member is that the planar seating sensor is on the first film layer side. A vehicle seat pad. The vehicle seat pad according to claim 1 or 2,
A vehicle is characterized in that a second film layer formed of a polyurethane elastomer raw material is further deposited between the mold foam and the seating sensor or the insert member disposed facing the mold foam. Seat pad. The vehicle seat pad according to any one of claims 1 to 3,
The vehicle seat pad according to claim 1, wherein the different types of polyurethane resins have different hardnesses. The vehicle seat pad according to any one of claims 1 to 4,
The vehicle seat, wherein the first coating layer formed in the lowermost layer is configured as a skin of a vehicle seat. A method for manufacturing a vehicle seat pad having a configuration in which different types of polyurethane resins are laminated,
A first film layer forming step of forming a first film layer by spraying or coating a polyurethane elastomer raw material in a mold;
A sensor installation step of installing a planar seating sensor for detecting the seating of an occupant on the first film layer in a stacked manner;
A mold foam forming step of injecting a polyurethane foam raw material onto the first film layer on which the seating sensor is installed, and foam-molding the mold foam by integrally bonding with the first film layer and the seating sensor. A method for manufacturing a vehicle seat pad, which is characterized. It is a manufacturing method of the seat pad for vehicles according to claim 6,
After the sensor installation step, an insert formed with a desired hardness corresponding to a support portion for supporting a seating load of an occupant on the seating sensor installed on the first film layer by the sensor installation step. The manufacturing method of the vehicle seat pad characterized by having the insert member installation process which installs a member. A method of manufacturing a vehicle seat pad according to claim 6 or 7,
After the sensor installation step or the insert member installation step, a polyurethane elastomer raw material is further sprayed or applied on the first film layer on which the seating sensor or the seating sensor and the insert member are installed, thereby forming the second film layer. The manufacturing method of the vehicle seat pad characterized by having a 2nd film layer shaping | molding process.

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