JP2008264037A - Cushion structure used for seat part and backrest part or the like of seat, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushion structure A which is manufactured inexpensively and is suitable for mass production. <P>SOLUTION: In the cushion structure A, the end of a net 20 spread to a frame-like member 10 constituting the frame of a seat part or backrest part or the like of a seat is wound around the frame part 11 of the frame-like member 10, and is fixed to the frame part of the frame-like member by the solidification of a thermoplastic resin in a melted state stuck to the surface of the frame-like member 10 through a cushion material 30 compressed by the tension of the net. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a cushion structure used for a seat portion, a backrest portion and the like of a seat and a manufacturing method thereof.

Conventionally, regarding this type of cushion structure, related techniques are disclosed in the following [Patent Document 1] to [Patent Document 3].
In [Patent Document 1], “the rigid frame that constitutes the composite frame in a state where each end of the net is wound on each frame portion of the composite frame in which the square frame-shaped rigid frame is embedded in the rectangular frame-shaped elastic frame. There is disclosed a “cushion structure body” in which the net is stretched around the composite frame fixed to each frame portion of the frame.

  [Patent Document 2] discloses a method of manufacturing the cushion structure disclosed in [Patent Document 1]. In this manufacturing method, “a net having a plate-like fixing member fixed to each end of the four sides is adopted as the net, and the composite frame is placed on the net in a state where the net is stretched flat. The net is tensioned by the pressing force from the frame, and each end of the net is wound on each frame portion of the frame, and is attached to each frame portion of the rigid frame constituting the frame. Means for stretching the net on the composite frame by fixing the fixing members are employed.

In [Patent Document 3], “a sheet that is cut larger than the area stretched on the frame-like member is clamped in a mold in which a recess corresponding to the shape of the frame-like member is formed. The sheet is formed by forming a film on the member with a molten thermoplastic resin, and fitting the frame-shaped member on which the film is formed into the recess of the mold from above the sheet, thereby cooling the mold. A seat tensioning method for a seat portion, a backrest portion, etc., in which the terminal of the seat is fixed to the frame portion by solidification of the film in a state where the terminal is wound around each frame portion of the frame-like member is disclosed. Yes.
Japanese Patent No. 3612461 JP 2001-186963 A Japanese Patent No. 3200409

  In the cushion structure described in [Patent Document 1], since the composite frame is configured by embedding a rigid frame in an elastic frame, the manufacturing cost is inevitably high and is not suitable for mass production. . Further, in the manufacturing method described in [Patent Document 2], each of the rigid frames is fixed in a state where the fixing member is fixed to each terminal of the sheet and the elastic frame constituting the composite frame is compressed with the fixing member. Since it is fixed to the frame portion, the number of assembling steps for the fixing member is large and is not suitable for mass production. Furthermore, in the sheet stretching method disclosed in [Patent Document 3], there is a defect that the molten resin protrudes from the mesh at each end of the sheet fixed to each frame portion of the frame-like member and impairs the appearance.

  In order to solve the above-described problems, the present invention wraps a terminal of a net stretched around a frame-like member constituting a frame such as a seat part or a backrest part of a seat around the frame part of the frame-like member. A seat portion of the seat, which is fixed to the frame portion of the frame-like member by solidification of a molten thermoplastic resin attached to the surface of the frame-like member via a cushion material compressed by the tension of A cushion structure used for a backrest portion or the like is provided.

 The present invention is characterized in that the following steps are employed in order to produce the cushion structure.

(1) A resin adhesion step in which a thermoplastic resin is adhered in a molten state to the surface of a frame-like member that constitutes a frame such as a seat portion and a backrest portion of a seat;
(2) a clamping step of clamping the net forming the sheet main body such as the seat portion and the backrest portion at the end thereof, and stretching the net flat;
(3) a positioning step of positioning a cushion material formed in a shape corresponding to the frame portion of the frame-shaped member on the stretched net;
(4) A pressurizing step of placing the frame-shaped member on the cushion material in a state where the thermoplastic resin adhering to the surface is molten and pressurizing the frame-shaped member from above;
(5) The end of the net is held in a state where the cushion material is compressed by the pressure of the frame-shaped member and the peripheral edge of the net is held between the cushion material and the supporting means disposed immediately below the cushion material. A step of releasing the pressurization of the frame-shaped member after the thermoplastic resin wound around the frame-shaped member via a cushion material and adhered to the frame-shaped member is solidified by cooling.

  In the cushion structure of the present invention, the end of the net stretched on the frame-shaped member is attached to the surface of the frame-shaped member via a cushion material compressed to the frame portion of the frame-shaped member by the tension of the net. The thermoplastic resin in a molten state adhered to was fixed to the frame portion of the frame member by solidification by cooling. As a result, even if the end of the net is fixed to the back surface of the frame-like member and the resin protrudes at the fixing portion, it may be detrimental because it is located on the lower side when used as a seat portion or a backrest portion of the seat. No. Further, since the molten resin is covered with the cushion material on the upper surface and the side surface of the frame portion of the frame-like member, it can be finished beautifully without protruding onto the surface of the net.

  In the method for manufacturing a cushion structure according to the present invention, a cushion material formed in a shape corresponding to the frame portion of the frame-like member is placed and positioned on a flatly stretched net, and the cushion material is placed on the cushion material. The frame-shaped member is placed in a state where the thermoplastic resin adhering to the surface is melted and pressed, so that the peripheral edge of the net is sandwiched between the compressed cushioning material and the supporting means disposed immediately below. Held in pressure. Thereby, the end of the net is wound around the frame-shaped member via the cushion material, and is accurately fixed to the back surface of the frame-shaped member by solidification by cooling of the resin.

  In the drawings, FIG. 1 is a sketch of a cushion structure A according to the present invention manufactured using the frame-like member 10 shown in FIG. 2 and the net 20 shown in FIG. In this cushion structure A, the end of a net 20 stretched around a frame-like member 10 constituting a frame such as a seat part and a backrest part of a seat is wound around the frame part 11 of the frame-like member 10 to tension the net. The molten thermoplastic resin R adhered to the surface of the frame-shaped member through the cushion material 30 compressed by the above is fixed to the frame portion of the frame-shaped member by solidification. As shown in FIG. 2, the frame-like member 10 used in this cushion structure constitutes the frame of the seat portion of the seat to be applied, and is a U-shape made of a metal pipe such as iron or aluminum. Frame portion 11 and a connecting pipe 12 coupled to both ends of the frame portion. The net 20 is a net obtained by weaving super-strong yarns such as polyester fiber, PTT fiber, polyester-based elastomer yarn, nylon fiber, etc., and has a shape corresponding to the outline of the frame-like member 10 as shown in FIG. It has been cut. The cushion material 30 is a cushion material made of urethane sponge, rubber sponge (NR, CR, EPPM, silicon, etc.), polyethylene sponge, polyolefin sponge, etc., and is formed in a shape corresponding to the frame portion 11 of the frame-shaped member 10. Yes.

  Below, the manufacturing method of the cushion structure by this invention mentioned above is demonstrated in detail. FIG. 4 shows an apparatus for manufacturing the cushion structure shown in FIG. The manufacturing apparatus includes a plurality of substrates 81 that are horizontally installed on a movable base 80 with wheels attached thereto and a periphery of an opening 81a provided on the upper surface of the substrate 81 in the center of the substrate. A clamping device 82, four sliders 83 disposed on the substrate 81 corresponding to each side of the opening 81a, and a pushing cylinder 84 for sliding the slider 83 toward the opening are provided. The opening 81a of the substrate 81 is formed in a shape corresponding to the frame-shaped member 10 so that the frame-shaped member 10 described above is arranged to be movable up and down.

  As shown in FIGS. 4 and 6, each clamp device 82 includes a support bracket 82 a fixed to the upper surface of the substrate 81, and a swing lever pivotally supported on the support bracket 82 a below the support bracket 82 a in a vertical direction. 82b, a clamper 82c provided integrally with the swing lever 82b, and an operation lever 82d that is pivotally coaxial with the swing lever 82b and pivotable in the vertical direction. The clamper 82c is pressed against a support 82e fixed to the upper surface of the substrate 81 in front of each support bracket 82a, and the end of the net 20 stretched so as to cover the opening 81 of the substrate 81 in a clamping process described later. Clamp. In this embodiment, a fixing plate 82f is fastened and fixed to the lower surface of the substrate 81 by a fastening screw 82g at a position corresponding to each support body 82e, and the end of the rubber sheet 90 is opened to the opening of the substrate 81 by these fixing plates 82f. It is fixed along the periphery of 81a. The rubber sheet 90 is disposed so as to cover the opening 81a of the substrate 81, and plays a role of elastically supporting the net 20 in a pressurizing process of the frame-like member 10 described later. The slider 83 has an elongated hole 83a for accommodating the support bracket 82a of each clamp device 82, and slides toward the opening 81a of the substrate on the upper surface of the substrate 81 by the operation of the pushing cylinder 84.

  A method of manufacturing the cushion structure of the present invention by the manufacturing apparatus configured as described above will be described below for each process.

  (1) In this embodiment, in order to adhere the thermoplastic resin to the surface of the frame-shaped member 10 in a molten state, the frame-shaped member 10 is attached by the heating coil 41 of the high-frequency heating device 40 shown in FIG. The heated frame-shaped member 10 is carried into the resin storage tank 50 shown in FIG. 8, and the thermoplastic resin powder SR suspended in a dust state inside the storage tank 50 is supplied to the frame-shaped member 10. Adhere to the surface. Thereby, a thermoplastic resin adheres to the surface of a frame-shaped member in a molten state. In this resin adhering step, when a steel pipe is used as the frame member 10, a polyester fiber net is used as the net 20, and polyethylene resin is used as the thermoplastic resin, the frame member 10 is about 300 mm. A preferable result was obtained by heating to a temperature of not less than 60 ° C. to adhere the polyethylene resin, and allowing the frame member to adhere to the cushion material 30 and the net 20 at a temperature of about 260 ° C. or less. In this regard, it is desirable to set the preheating temperature of the frame-shaped member when the polyethylene resin is adhered in consideration of the bonding time and the thickness of the resin.

  (2) On the other hand, as shown in FIGS. 5 and 6A, the net 20 shown in FIG. 3 is disposed so as to cover the opening 81a of the substrate 81, and its terminal is installed around the opening 81a. The plurality of clamp devices 82 are placed on the support bodies 82e and clamped by the clampers 82c by the operation of the operation levers 82d. Thereby, the net 20 is stretched flat in a state where the opening 81a of the substrate 81 is covered.

  (3) On the net 20 stretched flat by the above clamping process, as shown in FIG. 6A, a cushion material 30 formed in a shape corresponding to the frame portion 11 of the frame-shaped member 10 is formed. It is placed and positioned at a predetermined position.

  (4) Next, as shown in FIG. 6B, the frame-like member 10 in which the thermoplastic resin is melted on the surface by the residual heat in the above-described resin adhesion step is positioned on the net 20. The rib 11a, which is placed on the cushion member 30 and formed integrally with the inside of the frame-like member 10, is activated by the hydraulic cylinder 71 assembled to the pressure device 70 shown in FIG. Pressurized from above by legs 73 provided on the top. In this pressurizing step, the cushion material 30 is compressed by the applied pressure applied to the frame-like member 10 as shown in FIGS. 6 (c) and 6 (d), and the peripheral portion of the net 20 is the cushion material. 30 and a rubber sheet 90 disposed immediately below it is held under pressure. In this state, the cushion member 30 is bonded to the lower surface of the frame-shaped member 10 with a molten thermoplastic resin, and the net 20 is held in a tensioned state on the upper surface of the rubber sheet 90. When the net 20 is held in a tensioned state in this way, the clamper 82c is opened by the operation of the operation lever 82d of each clamp device 82 disposed around the opening 81a of the substrate 81, and each slider 83 is moved into the pushing cylinder 84. Is pushed forward, and the terminal of the net 20 is wound around the upper surface of the frame-like member 10 by the forward movement of each slider 83 and bonded by a molten thermoplastic resin. (See FIG. 6 (d)) After that, it is confirmed that the molten resin is solidified by cooling the frame-shaped member 10, and the respective pushing cylinders 84 are moved backward, whereby each slider 83 is moved to its original position. Pulled back to. Thus, the end of the net 20 is firmly fixed to the frame portion 11 of the frame-like member 10 via the cushion member 30, and the cushion structure according to the present invention can be carried out by raising the ram 72 of the pressure device 70. it can.

  As understood from the above matters, in this embodiment, the cushion material 30 formed in a shape corresponding to the frame portion 11 of the frame-like member 10 is placed and positioned on the net 20 stretched flat, and the cushion The frame-shaped member 10 is placed on the material 30 in a state where the thermoplastic resin adhering to the surface is melted and pressed, and the cushion material 30 in which the peripheral portion of the net 20 is compressed and its It is held under pressure by a supporting means made of a rubber sheet 90 disposed immediately below. As a result, the end of the net 20 is wound around the frame-shaped member 10 via the cushion material 30 and is accurately fixed to the back surface of the frame-shaped member 10 by the solidification of the resin.

  Therefore, according to the present invention, a desired cushion structure can be efficiently manufactured without using a conventional fixing member as compared with the cushion structure described in the section “Background Art”. . Further, in the above-described manufacturing process, the net 20 is held in a state where the peripheral portion of the net 20 is sandwiched and held by the support means including the cushion material 30 and the rubber sheet 90 disposed immediately below the pressurizing process. Is wrapped around the upper surface of the frame-like member 10 and bonded with a molten thermoplastic resin, so that even if the resin protrudes at the bonded portion of the net 20, the cushion structure is placed on the seat portion of the seat and the backrest portion. When it is used as it is located on the lower side, it does not impair the beauty of the product.

  In the above-described embodiment, the rubber sheet 90 is used as a means for supporting the peripheral portion of the net 20 that is pressed through the cushion material 30 in the pressing process of the frame-shaped member 10. As shown in FIG. 9, a support 92 that is elastically supported by a coil spring 91 may be provided on the base 80 by an appropriate means to support the peripheral edge of the net 20.

The sketch of the cushion structure by this invention. The top view of the frame-shaped member used for the cushion structure shown in FIG. The top view of the net | network used for the cushion structure shown in FIG. The front view which shows the manufacturing apparatus of the cushion structure by this invention. The top view which shows the clamp apparatus provided in the board | substrate shown in FIG. 4 with the same board | substrate. The partial cross section side view which shows the cushion structure manufacturing process by this invention. The schematic of the high frequency heating apparatus of the frame-shaped member shown in FIG. The schematic of the resin storage tank which makes a thermoplastic resin adhere to the frame-shaped member shown in FIG. The fragmentary sectional side view which shows the other Example of the net | network support means shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Frame-shaped member, 11 ... Frame part, 20 ... Net, 30 ... Cushion material, R ... Thermoplastic resin.

Claims (6)

  The end of the net stretched around the frame-shaped member constituting the frame such as the seat portion and the backrest portion of the seat is wound around the frame portion of the frame-shaped member and is compressed through a cushion material compressed by the tension of the net. A cushion structure characterized by being fixed to a frame portion of the frame-shaped member by solidification of a molten thermoplastic resin adhered to the surface of the frame-shaped member.   The cushion structure according to claim 1, wherein a metal pipe such as iron or aluminum is used as the frame member. A resin adhering step of adhering a thermoplastic resin in a molten state to the surface of a frame-like member constituting a frame such as a seat portion and a backrest portion of the seat;
A clamping step of clamping the net forming the seat body such as the seat portion and the backrest portion at the end thereof and stretching the net flat;
A positioning step of positioning a cushion material formed in a shape corresponding to the frame portion of the frame-shaped member on the stretched net; and
A pressing step of placing the frame-shaped member on the cushion material in a state where the thermoplastic resin adhering to the surface thereof is melted and pressurizing the frame-shaped member from above;
The cushion material is compressed by the pressure of the frame-shaped member, and the edge of the net is held by the cushion material and the supporting means disposed immediately below the cushion material. And the step of releasing the pressurization of the frame-shaped member after the thermoplastic resin that has been wound around the frame-shaped member and solidified by cooling is wound around the frame-shaped member. The manufacturing method of the cushion structure made to do.   The method for manufacturing a cushion structure according to claim 3, wherein a metal pipe such as iron or aluminum is employed as the frame member.   As a supporting means for supporting a peripheral portion of the net pressed through the cushion material in the pressurizing step of the frame-shaped member, the net is clamped at its terminal in the clamping step and stretched flat. 4. The method for manufacturing a cushion structure according to claim 3, wherein a rubber sheet disposed so as to support and support the net positioned immediately below the net is provided.   As a supporting means for supporting a peripheral portion of the net pressed through the cushion material in the pressurizing step of the frame-shaped member, the net is clamped at its terminal in the clamping step and stretched flat. 4. The method for manufacturing a cushion structure according to claim 3, wherein a supporting means is used that is positioned immediately below the net in an installed state so as to elastically support the net.

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