JP2009233263A - Manufacturing method of cushion body and seatback for vehicle using this cushion body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushion body which, even though a split face long enough to make the demolding smooth is formed when demolding a molded article as a cushion body, does not spoil the design formed by a skin material by the split face. <P>SOLUTION: When the cushion body is coated with the skin material 22, the split faces of a pendent flange part 17 and a side part flange part 15 respectively close the interspace with each other to form a close part 21. Moreover, the close part 21 is formed as an inclined face and the right and left side parts of the pendent flange part 17 is an inclined face in an inverted truncated chevron shape. Also, the inclined face of the side part flange part 15 is also an inclined face corresponding to the inclined face of the pendent flange part 17. Therefore, the pendent flange part 17 is supported by the side part flange part 15 at both sides, and it does not fall into a baglike concave point 14 even when a pressing force of the skin material 22 works. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a cushion body suitably used for an automobile seat back and a method for manufacturing an automobile seat back using the cushion body.

  In general, a seat back for an automobile is manufactured by covering a cushion body such as a polyurethane foam with a frame having a spring and then covering with a sewing skin material such as a fabric. On the back surface of such a cushion body, a flange portion is provided at least at the upper portion and the side portion, and a concave portion having a bag shape is formed by the flange portion. The cushion body is reinforced by incorporating a frame into the recess.

  The cushion body is molded by foaming and expanding a polyurethane raw material using a foam molding die 70 as shown in FIG. The cavity 74 of the foaming mold 70 is formed by an upper mold 72 and a lower mold 71 and a middle mold 73 provided therebetween. The middle mold 73 is for forming a recess on the back surface of the cushion body. Conventionally, since it becomes an obstacle when the molded product is removed from the middle mold 73, a flange portion cannot be formed at the lower part of the back surface of the cushion body. However, it is necessary to fix the frame also at the lower part of the back surface of the cushion body. For the fixing, a tongue piece is provided at a position that does not become an obstacle to demolding, and the tongue piece is bent to the lower side of the frame. However, when the elastic repulsive force of the tongue piece is strong, there is a problem that the tongue piece forms a raised portion on the surface of the skin material.

  As a solution to such a problem, Patent Document 1 discloses a cushion body provided with a flange portion extending inwardly in the upper, lower, left, and right sides of the back surface of the cushion body. A part of the middle mold that forms the flange portion at the bottom of the back surface of the cushion body is rotatably supported with respect to the middle mold body, and is rotated to a position where the flange section can be removed. Yes.

Moreover, in order to form a bag-shaped recessed part in the cushion body back surface, the cushion body which extended the upper part and the right and left flange part inside is disclosed by patent document 2. FIG. When the cushion body is removed from the mold, slits are formed at the corners of the upper flange portion and the left and right flange portions so that the flange portion is lifted from the middle mold and easily deformed.
Japanese Patent Laid-Open No. 60-240414 (see [FIG. 5]) Japanese Utility Model Publication No. 06-070645 (see [Summary])

  Although the flange part is formed in the lower part of the back surface of the cushion body in patent document 1, a slit is not formed in the corner part of the upper flange part and the flange part of a side part, or the slit is formed even if formed. It is formed in the horizontal direction. According to FIGS. 1 and 2 drawn as examples, what is called a slit is a wide gap so that it is more appropriate to call an opening rather than a slit. For this reason, when the cushion body is covered with the skin material, the positioning of the flange portions in the vicinity of the opening portion becomes unstable due to the air gap, and may be arranged unevenly. In addition, the passenger may feel uncomfortable by touching the gap through the skin material.

  Since the slit of the cushion body currently disclosed by patent document 2 does not have the clearance gap as the said cushion body, a passenger | crew does not feel discomfort. However, if the length of the slit is set to a length that is preferable in terms of molding technology such as demolding of the molded product, the flange portion between the slits is easily bent inward when pressed by the skin material. Therefore, there is a problem that a concave portion appears on the surface of the skin material.

  The present invention has been made paying attention to such a problem, and the object of the present invention is to have a sufficient length to enable smooth demolding when demolding a molded product as a cushion body. An object of the present invention is to provide a cushion body in which the slit does not impair the design formed by the skin material, although the slit is formed. Moreover, it is providing the manufacturing method of the seat back for motor vehicles using the cushion body.

  In order to solve the above-mentioned problem, the invention of the cushion body according to claim 1 is a cushion body of an automobile seat back provided with a flange portion that forms a bag-like recess on the back surface, and an upper portion on the upper back side of the cushion body. A hanging flange portion is formed which is divided at a corner portion formed by the flange portion and the side flange portions on the back side of the left and right side portions to form a part of the upper flange portion, and split surfaces on both sides of the hanging flange portion and The dividing surface of the side flange portion facing the dividing surface is an inclined surface inclined toward the side flange portion toward the surface of the depending flange portion in the thickness direction of the depending flange portion. To do.

  According to a second aspect of the present invention, in the cushion body according to the first aspect, the dividing surface is formed along a position corresponding to a sewing portion of a skin material sewn in accordance with the shape of the cushion body. It is characterized by being.

  According to a third aspect of the present invention, in the cushion body according to the first or second aspect, the tip of the hanging flange portion is in a natural state where it does not receive an external force from a surface connecting the surfaces of the left and right side flange portions. It is characterized by floating.

  According to a fourth aspect of the present invention, in the cushion body according to any one of the first to third aspects, the cushion body is covered with a skin material on each of the divided surfaces of the hanging flange portion and the side flange portion. When formed, the gaps are formed so as to close each other and close.

  An invention of a method for manufacturing a vehicle seat back according to claim 5 is a method for manufacturing a vehicle seat back using the cushion body according to any one of claims 1 to 4, wherein a polyurethane raw material is used. Injection into a foaming mold, forming a cushion body in which the tip of the hanging flange portion floats from the surface connecting the surfaces of the left and right side flange portions, covering the cushion body with a skin material, and the tip portion is Pressing the suspended drooping flange, and closing the dividing surface with the surface of the drooping flange and the surface of the side flange adjacent to the drooping flange having the same height It is.

(Function)
In the cushion body of the present invention, when the cushion body is covered with the skin material, the respective divided surfaces of the hanging flange portion and the side flange portion are closed with a gap therebetween. Moreover, the closed dividing surface is formed as a slope. The left and right side portions of the hanging flange portion are inclined surfaces that are inclined toward the side flange portion toward the surface of the hanging flange portion, and the inclined surface of the side flange portion is also an inclined surface corresponding to the inclined surface of the hanging flange portion. . Therefore, both sides of the hanging flange portion are supported by the side flange portions, and even if the pressing force of the skin material acts, the drooping flange portion does not fall into the bag-like recess.

  In the manufacturing method of the seat back for automobiles using the cushion body of the present invention, the hanging flange portion divided by the side flange portion and the dividing surface is formed, and the tip of the hanging flange portion is the left and right side flange portions. It is a requirement to form a cushion body that floats from the surface connecting the surfaces. The hanging flange part forms part of the upper flange part. Then, the cushion body is covered with a skin material and the hanging flange portion where the tip portion floats is pressed, and the surface of the hanging flange portion and the surface of the side flange portion adjacent to the hanging flange portion are the same. Make it tall. In this way, the dividing surface is closed, and the automobile seat back is manufactured in which the hanging flange portion does not fall into the bag-like recess due to the skin material pressing force.

  According to the present invention, when the molded product as the cushion body is removed from the mold, the divided surface is formed by the skin material even though the divided surface having a sufficient length that enables smooth demolding is formed. The cushion body which does not impair the formed design can be provided.

(First embodiment)
Hereinafter, embodiments of a cushion body embodying the present invention will be described with reference to FIGS. In addition, about the structure same as a prior art, the code | symbol same as the code | symbol used in the description shall be used. In addition, the top, bottom, left, and right used in the description with reference to FIGS.

  As shown in FIGS. 1A and 1B and FIG. 2, the cushion body 10 of the present embodiment is formed into a bag shape by a side flange portion 15, an upper flange portion 16, and a depending flange portion 17 on the back side of the backrest portion 13. The recess 14 is formed. The hanging flange portion 17 of the present embodiment is a part of the upper flange portion 16 divided at the corner portion 24 formed by the upper flange portion 16 on the back side of the upper portion 11 of the cushion body 10 and the side flange portion 15 on the back side of the side portion 12. It floats from the surface connecting the surfaces of the adjacent left and right side flange portions 15. That is, the drooping flange portion 17 becomes a valley-like body at the bent portion 17 c and is inclined with respect to the upper flange portion 16. Moreover, the drooping flange part 17 in this embodiment is formed in the corner | angular part 24 located inside the inner surface 15a of the side part flange part 15, and the surface shape is exhibiting the substantially rectangular shape as shown in FIG. Note that through holes 19 are formed at the left and right ends of the bent portion 17c so that the left and right side portions of the hanging flange portion 17 are not cracked from the portion connected to the upper flange portion 16 to the upper portion 11 side. Yes. The direction of the axial center of the through hole 19 has the same inclination as that of a split surface 17a described later.

  As shown in FIGS. 3 and 4, the tip end portion 17 b of the hanging flange portion 17 floats by a height h from the surface connecting the surfaces of the adjacent left and right side flange portions 15. Each dividing surface 15b in the left and right side flange portions 15 is a slope inclined toward the side flange portion 15 toward the surface of the depending flange portion 17 in the thickness direction. Further, the left and right dividing surfaces 17a of the drooping flange portion 17 also have slopes that incline toward the side flange portion 15 toward the surface of the drooping flange portion 17 in the thickness direction of the drooping flange portion 17 in the same manner as the dividing surface 15b. The left and right dividing surfaces 17a have an inverted C shape. The dividing surface 15b and the dividing surface 17a have the same inclination angle when the hanging flange portion 17 is pressed and abutted between the bent portion 17c and the tip portion 17b (state of FIG. 5). Is formed. The concave portions 20a formed on the surface portions of the flange portions of the dividing surface 15b and the dividing surface 17a become the concave portions 20 when they are joined. In addition, the recessed part 20 in this embodiment is formed along the division | segmentation surface 15b and the division | segmentation surface 17a, and is extended further to the upper part 11. As shown in FIG.

  As shown in FIG. 5, when the cushion body 10 is covered with the skin material 22, the hanging flange portion 17 that receives the pressing force of the skin material 22 is supported between the left and right side flange portions 15. At this time, the hanging flange portion 17 and the left and right side flange portions 15 form the same surface. And since the right-and-left closing part 21 is arrange | positioned in reverse C shape, the drooping flange part 17 does not fall further into the recess 14. FIG. In addition, since the sewing part 23 is accommodated in the recessed part 20 formed in the upper part of the closing part 21, a protruding item | line part is not formed when the sewing part 23 protrudes on the surface side of the skin material 22. FIG.

(Production method)
In order to manufacture an automobile seat back using the cushion body 10 of the present embodiment, first, as described above, the front end portion 17b of the hanging flange portion 17 connects the surfaces of the adjacent left and right side flange portions 15. The cushion body 10 which floats by the height h is formed. Next, after incorporating a frame or the like (not shown) into the recess 14 on the back side of the backrest 13 of the cushion body 10, the cushion body 10 is covered with the sewn skin material 22. At this time, the hanging flange 17 is pressed with the skin material 22 so that the hanging flange 17 is supported between the left and right side flanges 15. And if the surface of the drooping flange part 17 and the surface of the left and right side flange parts 15 are made the same height, the seat back for an automobile is completed.

(Mold structure)
The molding die for foam-molding the cushion body 10 of the present embodiment has almost the same configuration as the conventionally known foam molding die 70 shown in FIG. 8, and the cushion body 10 is formed by a lower die 71, an upper die 72 and a middle die 73. The cavity 74 is molded. However, since the part which shape | molds the drooping flange part 17 differs, it demonstrates using FIG. Note that the cross-sectional view shown in FIG. 6 is a part for molding the vicinity of the tip 17b of the hanging flange part 17, and shows only the right part in the direction of arrow A in FIG.

  As shown in FIG. 6, the middle mold 73 and the upper mold 72 are configured such that the cavity 75 and the drooping flange section for forming the side flange section 15 are formed at the part where the parting surface 73 c formed by the inclined surface and the parting surface 72 c meet. The cavity 77 for molding 17 is separated. The cavity 77 includes a molding surface 72d that molds the surface of the hanging flange portion 17, a projection 72a that molds the recess 20a, a slope 73d that molds the dividing surface 17a, and a molding surface 73e that molds the inner surface of the hanging flange portion 17. And more formed. The cavity 75 includes a molding surface 72e for molding the surface of the side flange portion 15, a convex portion 72b and a convex portion 73b for molding the concave portion 20a, a slope 73a for molding the split surface 15b, and the side flange portion 15. And a molding surface 73f for molding the inner surface. The inclined surface 73d and the inclined surface 73a are substantially the same inclined surface.

  Although not shown, the butting portion 76 protruding from the middle mold 73 in the upper right direction in the drawing is tapered at a position corresponding to the bent portion 17c, and a round bar-like body for forming the through hole 19 at the end thereof. Are connected. Note that the position corresponding to the bent portion 17c is in the direction of the back side of the sheet of FIG.

Therefore, according to the cushion body of the above-described embodiment and the method for manufacturing an automobile seat back using the cushion body, the following effects can be obtained.
(1) In the above embodiment, each of the left and right dividing surfaces 15b and the pair of dividing surfaces 17a is formed to have an inverted C shape in FIG. Therefore, when the cushion member 10 is covered with the skin material 22 and the dividing surface 15b and the dividing surface 17a are closed, the hanging flange portion 17 is supported between the left and right side flange portions 15 and falls into the recess 14. It is prevented. Therefore, the cushion body 10 which keeps the design of the back side as a seat back for automobiles can be provided.

  (2) In the above embodiment, the recess 20 is formed along the upper ends of the dividing surface 15b and the dividing surface 17a so that the sewing portion 23 of the skin material 22 can be accommodated. Therefore, when the cushion body 10 is covered with the skin material 22 and the hanging flange portion 17 is supported between the left and right side flange portions 15, the space between the surface of the side flange portion 15 and the surface of the hanging flange portion 17 is between. Even if a slight level difference occurs, the level difference is hidden inside the sewing portion 23. Therefore, the cushion body 10 which keeps the design of the back side as a seat back for automobiles can be provided.

  (3) In the above embodiment, the cushion body 10 is formed so that the tip end portion 17b of the hanging flange portion 17 floats from the surface connecting the surfaces of the left and right side flange portions 15 in a natural state where no external force is applied. Therefore, in the foam mold, the mold structure for molding the portion of the cushion body 10 can be easily formed by the abutting portion between the upper mold 72 and the middle mold 73.

(Example of change)
In addition, you may change the said embodiment as follows.
In the above-described embodiment, the hanging flange portion 17 has the split surface 17a formed at the corner portion 24 located on the inner side of the inner side surface 15a of the side flange portion 15, and the surface shape thereof is substantially rectangular. However, as shown in FIG. 7, the dividing surface 17 a extends outward from the corner portion 24 between the tip end portion 17 b of the hanging flange portion 17 and the inner side surface 15 a of the side flange portion 15 toward the upper portion 11 side. The surface shape of the hanging flange portion 17 may be a substantially inverted trapezoid.
In the above embodiment, the distal end portion 17b of the hanging flange portion 17 floats from the surface connecting the surfaces of the left and right side flange portions 15 in a natural state where no external force is applied. You may form so that the surface and the surface of the side flange part 15 on either side may become substantially the same height. At that time, a resin sheet that is non-adhesive to the polyurethane raw material may be inserted between the upper mold 72 and the middle mold 73 in order to form the divided surface 17a and the divided surface 15b.
In the above-described embodiment, the concave portion 20 is provided so that the sewing portion 23 of the skin material 22 can be accommodated. However, when the sewing portion 23 does not exist in the portion of the skin material 22, or even if the sewing portion 23 exists, When the influence on the design of the material is small, the recess 20 is not necessarily provided.

The cushion body of embodiment of this invention is shown, (a) shows a backrest part side, (b) is a perspective view which shows a recess side. The rear view which shows a part of back side of a cushion body. Sectional drawing which shows typically the cross section of A arrow of FIG. FIG. 4 is a partial cross-sectional view schematically showing a cross-section as viewed from arrow B in FIG. 3. The partial cross section figure of drooping flange part vicinity when a skin material is coat | covered to the cushion body. Sectional drawing which shows a part of shaping | molding die. The rear view which shows a part of back side of the cushion body of the example of a change. Sectional drawing which shows the foaming mold of a prior art.

Explanation of symbols

  h ... Height, 10 ... Cushion body, 11 ... Upper part, 12 ... Side part, 15 ... Side flange part, 15b, 17a ... Split surface, 16 ... Upper flange part, 17 ... Drooping flange part, 17b ... Tip part, 20, 20a ... concave portion, 22 ... skin material, 23 ... sewing portion, 24 ... corner portion, 70 ... foaming mold, 73a, 73d ... slope.

Claims (5)

  In the cushion body of an automobile seat back provided with a flange portion that forms a bag-like recess on the back surface, a corner portion formed by an upper flange portion on the upper back side of the cushion body and a side flange portion on the left and right side back sides A hanging flange portion is formed that forms a part of the upper flange portion, and the divided surfaces on both sides of the hanging flange portion and the divided surfaces of the side flange portions facing the divided surfaces are the hanging flanges. A cushion body characterized in that the cushion body is a slope inclined toward the side flange portion toward the surface of the hanging flange portion in the thickness direction of the portion.   2. The cushion body according to claim 1, wherein the divided surface is formed along a position corresponding to a sewing portion of a skin material sewn in accordance with a shape of the cushion body.   The cushion body according to claim 1 or 2, wherein a tip of the hanging flange part floats from a surface connecting surfaces of the left and right side flange parts in a natural state where no external force is applied.   4. The respective split surfaces of the hanging flange portion and the side flange portion are formed so as to close and close each other when the cushion body is covered with a skin material. The cushion body as described in any one of these.   A method for manufacturing an automobile seat back using the cushion body according to any one of claims 1 to 4, wherein a polyurethane raw material is injected into a foaming mold, and a tip end of the hanging flange portion is the left and right sides. Forming a cushion body that floats from the surface connecting the surfaces of the side flange portions, and covering the cushion body with a skin material and pressing the suspended flange portion where the tip portion floats, and the surface of the suspended flange portion and the suspended portion A method for manufacturing a seat back for an automobile, wherein the side surfaces of the side flange portions adjacent to the flange portions are made to have the same height and the divided surfaces are closed.

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