JP2009090549A - Sheet pad, its manufacturing process, and manufacturing process of sheet component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foam-molding process of sheet pad equipped with a protruded part directing to the inner part which is constructed uniformly on a back part from a back side of a pad body, while lacking a material of the pad is suppressed. <P>SOLUTION: In a sheet pad 10 equipped with a pad body part 16 composed of a flexible foam and a protruded part 18 directing to the inner part from the back side of the pad body part 16, the protruded part 18 is provided with a pair of slits 24, 24, and a foam-molding of the sheet pad 10 is conducted under such conditions that in the protruded part 18, a part 22a surrounded with the pair of slits 24, 24 is raised in a further back direction Z1 than other parts 22b, 22b, and then a surface skin 5 is covered under such conditions that in the brattice part 18, the part 22a surrounded with the pair of slits 24, 24 is pressed into front direction Z2 to deform the same. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a seat pad that is a cushion body mainly used for an automobile seat, a manufacturing method thereof, and a manufacturing method of a seat constituent member using the seat pad.

  Conventionally, seat pads made of foamed resin such as polyurethane called back pads and cushion pads used for backrests and seats of automobile seats are assembled to mounting steel materials such as metal frames, and the pad surface is By being covered and covered with a skin material, it is configured as a part of a vehicle seat.

  For example, in the seat pad 100 used for the backrest portion as shown in FIG. 6, in order to hold the mounting steel material, the pad main body portion 102 that supports the back, and the overhang portion 104 that is integrally extended from the back side, And a projecting portion 104 extending rearward from the upper side portion on the back side of the pad main body portion 102, and an inner side (a predetermined distance from the back surface of the pad main body portion 102 from the connection portion 106). And a flange portion 108 extending downward), and may be formed into a bag shape that opens downward as a whole (see, for example, Patent Document 1 below).

When foam-molding such a sheet pad 100, as shown in FIG. 7, the lower mold 122 that molds the front side of the sheet back pad 100 and the inside of the overhanging portion 104 on the back side of the sheet pad 100 are molded. A three-part foaming mold 120 comprising an upper mold 126 that is integrally provided with a core mold 124 and that can be closed to the lower mold 122 is used. During foam molding, the foamed resin stock solution 128 is injected into the lower mold 122, the upper mold 126 is closed together with the core mold 124 to the lower mold 122, and the cavity 132 corresponding to the pad shape is formed inside the mating surface 130. The foamed resin stock solution 128 is filled and foamed.
JP-A-11-99528

  When foam molding is performed on the sheet pad 100 having the inwardly extending portion 104 using the above foam molding die 120, the foamed resin stock solution 128 injected into the lower mold 122 is a lower mold that forms the connecting portion 106. The space between the upper mold 126 and the core mold 124 that forms the flange portion 108 around the tip of the core mold 124 as indicated by an arrow F from the space S1 between the core mold 124 and the core mold 124. It will flow into the space S2. Therefore, when the sheet pad 100 having a large folding angle of the overhanging portion 104, that is, the angle θ of the flange portion 108 with respect to the connecting portion 106 is, for example, 90 ° or more is foam-molded using the above-described foam molding die 120, foaming is performed. However, the foamed resin stock solution 128 with increased viscosity has to go around the core mold 124 by a large angle corresponding to the folding angle θ of the overhanging portion 104, and it is difficult to mold the flange portion 108 with high accuracy. is there.

  In particular, when the flange portion 108 is provided with a thick portion 108a that becomes thicker toward the rear, the upper die 126 is formed with a recessed portion 126a that is depressed upward to form the thick portion 108a. Since a gas such as foaming gas or air is likely to accumulate in the recessed portion 126a that is recessed upward, a thin portion is likely to occur in the thick portion 108a. Such a lacking wall appears as an uneven shape through the skin covering the surface of the sheet pad 100, and is unnatural. Therefore, a repair work such as filling the lacking part with a foam is necessary, which increases the number of work steps. There is.

  The present invention has been made in view of the above points, and is a sheet pad including an inwardly extending portion that is integrally extended rearward from the back surface side of the pad main body portion, while suppressing the occurrence of a lack of thickness. It is an object of the present invention to provide a foam molding method, a sheet pad obtained by the method, and a method for producing a sheet constituent member using the sheet pad.

  A method for manufacturing a pad for a sheet according to the present invention is provided for a sheet comprising: a pad main body portion made of a flexible foam; and an inwardly extending portion integrally extending rearward from a side portion on the back side of the pad main body portion. The pad manufacturing method is characterized in that a pair of slits are provided in the overhanging portion, and foam molding is performed in a shape that causes the portion sandwiched between the pair of slits in the overhanging portion to be caused behind the other portions.

  In the manufacturing method of the present invention, the overhanging portion sandwiched between the pair of slits is foam-molded in a shape that is caused behind the other portions, so that the folding angle of the overhanging portion is reduced in the portion caused behind, and foaming is performed. Since the angle at which the resin stock solution wraps around the mold surface that molds the inner surface of the overhanging portion becomes small, the liquid resin stock solution is smooth and the moldability is improved.

  In particular, for a sheet using a three-part type foam molding die comprising a lower die for forming the pad main part, an upper die for forming the outside of the overhanging portion, a core die for forming the inside of the overhanging portion, and When the pad is foam-molded, the mating surface of the upper mold and the core mold is located at the tip of the overhanging portion, so that the mating surface can be positioned upward. It is easy to remove the gas such as foaming gas and air contained therein, and the occurrence of lacking wall can be suppressed.

  The present invention also provides a sheet pad obtained by the above-described manufacturing method, that is, the sheet pad according to the present invention includes a pad main portion made of a flexible foam and a back side of the pad main portion. A pad for a sheet comprising an inwardly extending portion integrally extending rearward from the side portion, and the protruding portion is divided into a plurality of portions by a pair of slits, and a portion sandwiched between the pair of slits It is characterized in that it has a shape caused behind the other parts.

  Furthermore, the present invention is a method of manufacturing a sheet constituent member that covers at least a part of a sheet by covering the surface of the sheet pad obtained by the above manufacturing method, and a pair of slits in the overhanging portion. The sheet pad is foam-molded in a shape that causes the portion sandwiched between the pair of slits in the overhanging portion to be rearward of the other portions, and the portion sandwiched between the pair of slits in the overhanging portion is formed The epidermis is covered in a state of being pushed forward and deformed.

  In the sheet component manufacturing method of the present invention, a pair of slits are provided in the overhanging portion of the sheet pad so that the portion sandwiched between the pair of slits in the overhanging portion is easily pushed forward and deformed. The surface of the pad for sheeting can be covered with the portion sandwiched between the slits being pushed forward and deformed so that the outer surface matches the other surface. As a result, the sheet pad can be formed in a shape that is easy to be foam-molded, and the sheet pad can be deformed when covering the skin to obtain a sheet-constituting member having a desired shape.

  According to the present invention, since the liquid periphery of the foamed resin is improved, molding defects such as lacking can be greatly reduced, the defect rate and repair rate of the product can be reduced, and the cost can be reduced. .

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a perspective view showing a sheet constituent member 2 obtained by a manufacturing method according to an embodiment of the present invention, FIG. 2 is a perspective view of a sheet pad 10, and FIG. 3 is a cross-sectional view taken along line AA in FIG. 4 is a cross-sectional view of a foam molding die 50 for forming the sheet pad 10, and FIG. 5 is an enlarged cross-sectional view of a main part of the sheet constituent member 2 for explaining a process of covering the sheet pad 10 with the skin 5.

  As shown in FIG. 1, the seat constituent member 2 constitutes a backrest portion in a front seat 1 of an automobile, and includes a mounting steel material 3 such as a metal frame, and a seat pad 10 assembled to the mounting steel material 3. And a skin 5 made of woven or knitted fabric or leather that covers the surface of the seat pad 10. In FIG. 1, reference numeral 6 denotes a seat constituent member that supports a seated person's buttocks in the front seat 1, and includes a mounting steel material 7, a cushion pad 8 assembled to the mounting steel material 7, and a surface of the cushion pad 8. Since it has a cover 9 made of woven or knitted fabric or leather to be covered and can use the same structure as that of the seat constituting member 2 constituting the backrest portion, detailed description thereof will be omitted.

  As shown in FIGS. 2 and 3, the seat pad 10 includes a pad body 12 made of a flexible polyurethane foam, and a reinforcing cloth 14 laminated and integrated on the inner surface thereof. Overhang portions 18 for mounting the mounting steel material 3 are formed on the three sides of the upper side and the left and right sides of the back side of the pad main body 16 that supports the back of the seated person.

  Specifically, the overhanging portion 18 extends inwardly from the connecting portion 20 so as to protrude from the back Z1 of the pad main body portion 16 and the back surface of the pad main body portion 12 so as to have a predetermined distance. The seat pad 10 is formed in a bag shape that opens downward X1.

  The upper flange portion 22 a facing the upper side portion of the pad main body portion 16 becomes thicker toward the rear in the thick portion 26 formed at the substantially central portion in the vertical direction X of the sheet pad 10, and the front end is thicker than the thick portion 26. As it goes to, it is gradually formed thinner. Further, as shown in FIG. 5, the seat pad 10 is bent toward the front Z <b> 2 of the seat pad 10 in a state where the seat pad 10 is assembled to the mounting steel 3 and the skin 5 is covered. The angle φ1 of the inner surface of the tip 23 with respect to the inner surface of the upper flange portion 22a is set to 15 ° to 30 °, for example.

  The reinforcing cloth 14 is sewn in a bag shape and is integrated by polyurethane foam foam molding so as to cover the back surface of the pad main body portion 16 and the inner side surface of the overhang portion 18. The reinforcing cloth 14 can be used without any particular limitation as long as it has an appropriate air permeability and can prevent the polyurethane foam from oozing out during molding. These laminated composites can be used.

  In order to manufacture the above-described sheet component 2, first, the sheet pad 10 provided with a pair of slits 24, 24 in the flange portion 22 is foam-molded.

  More specifically, as shown in FIGS. 2 and 3, the flange portion 22 includes an upper flange portion 22 a facing the upper side portion of the pad main body portion 12 and side flanges facing both side portions of the pad main body portion 12. A pair of slits 24 and 24 are provided to separate the three portions 22b and 22b, so that the overhanging portion 18 is integrally formed with the pad main body portion 16 with the flange portions 22a, 22b and 22b being isolated from each other. Has been.

  The upper flange portion 22a has a shape that is caused in the rear Z1 from the side flange portions 22b and 22b with the connecting portion 20 side as a fulcrum, and the folding angle of the upper flange portion 22a, that is, the inner surface of the connecting portion 20 The angle θ of the inner surface of the upper flange portion 22a is set to be smaller than 90 °, for example, set to 60 ° to 80 °. Further, the tip 23 of the upper flange portion 22a is also caused to the rear Z1, and the angle φ2 of the inner surface of the tip 23 with respect to the inner surface of the upper flange 22a is set to 5 ° to 10 °, for example. The angle is set to be smaller than the angle φ1 of the inner surface of the distal end portion 23 with respect to the inner surface of the upper flange portion 22a in the state of being attached to the mounting steel material 3 and covering the skin 5.

  In order to perform foam molding of the sheet pad 10 in which such an upper flange portion 22a is caused in the rear Z1, a foam molding die 50 as shown in FIG. 4 is used.

  The foaming mold 50 includes a lower mold 52 that is recessed so as to mold the pad main body 16, and an upper mold that is rotatably provided via a hinge portion 54 disposed on one side of the lower mold 52. 56.

  The upper die 56 is a die that molds the back side of the pad main body portion 16, and is provided with a recessed portion 57 that is depressed upward in order to form the thick portion 26 of the upper flange 22 a. A core die 58 is integrally formed to form a pad shape between the lower die 52 inside the mating surface 53 by closing the upper surface opening of the lower die 52, that is, the upper flange portion 22a. Forms a cavity 82 as a foaming space corresponding to the shape of the pad for the sheet caused by the rear Z1. Further, a pair of slit forming pieces (not shown) for forming the slits 24, 24 project from the inner surface of one of the upper mold 56 and the core mold 58 that form the overhanging portion 18.

  In order to foam-mold the sheet pad 10 using the foam molding die 50, first, the reinforcing cloth 14 is placed on the core die 58, and fixed to the upper die 56 side by fixing with a pin (not shown). Next, the foamed resin stock solution 80 is injected into the lower mold 52 using an injection device (not shown), and then the upper mold 56 is closed with respect to the lower mold 52. As a result, the foamed resin stock solution 80 wraps around the tip of the core mold 58 from the space S1 between the lower mold 52 and the core mold 58 forming the connecting portion 20, as indicated by an arrow F in FIG. Thus, the flange portion 22 formed between the upper die 56 and the core die 58 flows into the space S2 for molding, and fills the cavity 82 of the foam molding die 50.

  At that time, the sheet pad 10 has the upper flange portion 22a raised rearward so that the folding angle θ is set small, and the angle at which the foamed resin stock solution 80 wraps around the core mold 58 becomes small. The rotation is smooth and the moldability of the upper flange portion 22a is improved. In the foam molding die 50, the mating surface 53 can be disposed at a high position in the foaming space by providing the mating surface 53 of the upper die 56 and the core die 58 at the tip of the upper flange portion 22a. Therefore, a gas such as foaming gas or air contained in the foamed resin stock solution 80 is less likely to stay in the recessed portion 57 and is easily discharged from the mating surface 53, thereby further reducing the thickness of the thick portion 26. It becomes difficult to occur. Moreover, in order to perform foam molding in a state in which the front end portion 23 of the upper flange portion 22a bent toward the back surface of the pad main body portion 16 is raised backward, the mating surface 53 of the lower die 52 and the upper die 56, and the upper die The convex amount H of the recessed portion 57 between the mating surface 53 of the core 56 and the core mold 58 can be reduced (see FIGS. 4 and 7), and the liquid foam resin solution 80 in the recessed portion 57 can be obtained. The circumference can be improved and the moldability of the thick portion 26 can be improved.

  After foaming the sheet back pad 10 in this way, the upper mold 56 is opened and the sheet pad 10 is removed.

  Next, as shown in FIG. 5, after the removed sheet pad 10 is assembled to the mounting steel material 3, the upper flange portion 22a indicated by the alternate long and short dash line in FIG. The upper flange portion 22a is elastically deformed so that the folding angle θ is increased by pushing it into the front Z2 with the contact point with the mounting steel material 3 on the connecting portion 20 side as a fulcrum, and the outer surface of the upper flange portion 22a is set to the side flange portion 22b. , 22b, the above-described sheet component 2 is obtained by suspending the skin 5 on the surface of the sheet pad 10 and covering the surface 5 closely.

  As described above, in the present embodiment, by providing the pair of slits 24 and 24 in the overhanging portion 18 of the seat pad 10, the folding angle θ of the upper flange portion 22a caused in the rear Z1 is increased. It becomes easy to deform. Therefore, by forming the sheet pad 10 in a shape that facilitates foam molding, a sheet configuration having a desired shape in which the folding angle is large and the thick portion 26 is formed in the upper flange portion 22a while suppressing molding defects such as lack of thickness. The member 2 can be obtained, the defective rate and repair rate of the product can be reduced, and the cost can be reduced.

It is a perspective view which shows the sheet | seat structural member obtained by the manufacturing method in one Embodiment of this invention. It is a perspective view of the pad for sheets concerning one embodiment of the present invention. It is AA sectional drawing of FIG. It is a principal part expanded sectional view of the foam molding die which shape | molds the pad for sheets which concerns on 1 embodiment of this invention. It is a principal part expanded sectional view of the sheet | seat structural member explaining the process of coat | covering a skin with the pad for sheet | seats concerning one Embodiment of this invention. It is sectional drawing of the conventional pad for sheets. It is a principal part expanded sectional view of the foaming mold which shape | molds the conventional pad for sheets.

Explanation of symbols

DESCRIPTION OF SYMBOLS 2 ... Sheet | seat structural member 3 ... Mounting steel material 5 ... Skin 10 ... Sheet pad 12 ... Pad main body 16 ... Pad main-body part 18 ... Overhang | projection part 20 ... Connection part 22 ... Flange part 22a ... Upper flange part 22b ... Side flange part 24 …slit

Claims (3)

In a method of manufacturing a pad for a sheet, comprising: a pad main body portion made of a flexible foam; and an inwardly extending portion integrally extending rearward from a side portion on the back side of the pad main body portion.
A method of manufacturing a pad for a sheet, comprising: forming a pair of slits in the overhanging portion, and foam-molding a portion of the overhanging portion that is sandwiched between the pair of slits behind the other portion. In a pad for a sheet comprising: a pad main body portion made of a flexible foam; and an inwardly projecting portion integrally extended rearward from a side portion on the back side of the pad main body portion,
The pad for a sheet is characterized in that the projecting portion is divided into a plurality of portions by a pair of slits, and a portion sandwiched between the pair of slits has a shape that is raised rearward from the other portions. A pad for a sheet made of a flexible foam in which an inward projecting portion is integrally extended backward from a side on the back side of the pad main body, and a skin covering the surface of the sheet pad, In the manufacturing method of the sheet constituent member constituting at least a part,
A pair of slits is provided in the overhang portion, and the pad for the sheet is foam-molded in a shape that causes the portion sandwiched between the pair of slits in the overhang portion to be rearward from the other portion,
A method for manufacturing a sheet constituent member, wherein the skin is covered in a state where a portion sandwiched between the pair of slits is pushed forward and deformed in the overhanging portion.

Images