JP2010193922A - Seat pad - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a seat pad having a seat pad body comprising soft foamed resin and separate members arranged in the rear face side of the seat pad body and generating no foreign sound by sliding contact of the separate members and a seat frame or others. <P>SOLUTION: The seat pad has the seat pad body comprising the soft foamed resin, the separate members arranged in the rear face side of the seat pad body, and a supporter material covering at least a part of the rear face of the seat pad body or at least a part of the separate members, and soft foamed resin introducing parts contacting with both the supporter material and the separate members are locally arranged in at least one position of the separate members. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a seat pad suitable as a vehicle seat pad, and more particularly to a seat pad including a seat pad main body made of a soft foamed resin and another member disposed on the back side of the seat pad main body.

  Vehicle seat pads used in automobiles and the like are usually made of polyurethane foam. However, Patent Document 1 discloses the formation of polystyrene foam that is lighter than polyurethane foam on the back surface of the side support portion of the seat pad main body made of polyurethane foam. A urethane sheet pad fitted with a body is described. Patent Document 2 describes a cushion pad for an automobile seat in which an insert having an inverted U-shaped cross section made of highly foamed polyolefin is held inside a mold, and polyurethane foam is foamed. Patent Document 3 describes a cushion pad in which a polyethylene foam is held as an insert material inside a mold and polyurethane foam is foamed to form a pad of different hardness.

  In a seat pad in which a foamed polystyrene is fitted to the back surface as in Patent Document 1, an abnormal noise is generated when the foamed polystyrene comes into sliding contact with a seat frame or the like. Note that foamed polystyrene and foamed polyethylene are more likely to generate abnormal noise due to sliding contact than polyurethane foam.

  The cushion pad for an automobile seat described in Patent Document 2 has an insert with an inverted U-shaped cross section made of a highly foamed polyolefin, and its closed side end is located within the ridge of the side support, and its open side end. Since the cushion pad-shaped polyurethane foam is embedded so as to be flush with the back surface of the main body, abnormal noise is generated when the insert comes into sliding contact with the seat frame or the like.

  Patent Document 3 shows a cross-sectional view in which a polyethylene foam is surrounded by a polyurethane foam, and the polyethylene foam and the seat frame are not in sliding contact with each other. There is no description as to whether foam molding of polyurethane foam is performed while being held inside the mold.

JP-A-5-57069 No. 3-49555 Japanese Patent Laid-Open No. 1-249312

  The present invention is a seat pad comprising a seat pad body made of a soft foam resin and another member disposed on the back side of the seat pad body, and abnormal noise is caused by sliding contact between the other member and the seat frame or the like. An object is to provide a seat pad that does not occur.

  The present inventors diligently studied the structure of the seat pad in which the separate member and the seat frame or the like are not in direct sliding contact and no abnormal noise is generated. As a result, noise is no longer generated by providing a supporter material in a portion where the separate member and the seat frame or the like have been in sliding contact with each other, and the supporter material that does not adhere to the separate member and the separate member. It has been found that the soft foamed resin introduction portion serves as an adhesive portion between the separate member and the supporter material by locally providing the soft foam resin introduction portion in contact with both at least one part of the separate member. . In addition, when a soft foam resin introduction portion is locally provided, when a seat pad is molded, a part of the seat pad molding die that does not have a soft foam resin introduction portion is provided as a supporter material. It has also been found that the separate member can be positioned inside the molding die because of contact with each other.

The present invention has been further improved based on the above findings, and the gist of the present invention is as follows.
(1) a seat pad body made of a soft foam resin;
Another member disposed on the back side of the seat pad body;
A supporter material covering at least a part of the back side of the seat pad body and at least a part of the separate member;
With
The seat pad, wherein the separate member locally has at least one soft foamed resin introduction portion in contact with both the supporter material and the separate member.

(2) The seat pad according to (1), wherein the separate member is a molded body by bead foaming.

(3) The above-mentioned (1), wherein the area of the portion of the soft foam resin introduction portion that contacts the supporter material is 5 to 95% with respect to the area of the supporter material covering the separate member Or the seat pad of (2) description.

(4) The seat pad body made of the soft foamed resin has a front side portion and a back side portion, and the back side portion has an upper edge portion and left and right side edge portions, and the upper edge portion and The left and right side edge portions project toward the center of the back side portion, and form a bag-like cavity that opens toward the center on the back side of the seat pad body, The seat pad according to any one of (1) to (3) above.

  According to the invention of (1) above, since the separate member and the seat frame and the like are in sliding contact with each other via the supporter material, it is possible to prevent the generation of abnormal noise, and the supporter material that does not adhere to the separate member The supporter material can be fixed at the soft foamed resin introduction portion by locally providing the soft foamed resin introduction portion in contact with both the supporter material and the separate member, so that the supporter can be fixed. When the edge of the material undulates or the supporter material hangs down in a bag shape, and the work that attaches the seat pad to the seat frame, etc., the undulated part of the supporter material or the part that hangs down in the bag shape becomes a seat frame component, etc. It is possible to prevent the supporter material from being damaged by being caught. In addition, since the soft foam resin introduction portion is locally provided, when the seat pad is molded, the portion where the soft foam resin introduction portion is not provided is provided with a supporter material on the surface of the seat pad molding die. Therefore, the separate member can be positioned inside the molding die, and the separate member can be embedded in the back surface side of the seat pad main body with high accuracy.

  According to the invention of (2) above, even if a bead foam that is generally lighter than the soft foam resin but has a significantly poor adhesion to the soft foam resin is used as a separate member, Supporter material can be fixed at this soft foamed resin introduction part due to the anchor effect, so the end of the supporter material undulates or the supporter material hangs down in a bag shape, and the work to attach the seat pad to the seat frame, etc. It is possible to more reliably prevent the supporter material from being damaged by hooking the wavy portion of the supporter material or the bag-like portion of the seat frame to the seat frame parts or the like.

  According to the invention of (3) above, it is particularly advantageous when a seat pad having a specification with a wide area covering another member of the supporter material is required. In this case, when the area of the portion in contact with the support material of the soft foam resin introduction portion exceeds 95% with respect to the area where the support material covers the separate member, when the separate member is disposed in the seat pad molding die The contact area between the separate member and the surface of the mold for molding the seat pad is reduced, so that the positioning accuracy of the separate member is lowered, and as a result, the embedded position accuracy of the separate member disposed on the molded seat pad is lowered. To do. And the thickness of another member becomes thin depending on a site | part, and the durability of another member falls, The tendency is remarkable when another member is made into foaming styrene which is easy to break. On the other hand, if the area of the portion in contact with the support material of the soft foam resin introduction portion is less than 5% with respect to the area where the support material covers the separate member, the area where the support material is not fixed to the soft foam resin introduction portion However, there is a problem that waviness at the end of the supporter material and bag-like sagging of the supporter material are likely to occur. Therefore, it is preferable that the area of the portion in contact with the supporter material of the soft foam resin introduction portion is in the range of 5 to 95% with respect to the area where the supporter material covers another member. More preferably, it is 20 to 60%.

  According to the invention of (4) above, in the seat pad that forms the bag-shaped cavity that opens toward the center of the back surface, the waviness at the end of the supporter material and the bag-like sagging of the supporter material are particularly generated. Even if it is a bag-like hollow part which is easy to do, it can prevent advantageously the wave | undulation of the edge part of a supporter material and the bag-like sagging of a supporter material. And when the seat pad having such a hollow portion is used as a back pad, for example, the hollow portion is located in a place where it is difficult to look into, so the undulation at the end of the supporter material or the bag-like sag of the supporter material is found. Therefore, the invention of (4) above, which can prevent the end portion of the supporter material from wavy and the supporter material from sagging in the bag shape, is particularly useful.

It is a top view of a seat pad which is a 1st embodiment of the present invention. It is sectional drawing which follows the II line | wire of FIG. It is an enlarged view of the right side support part in FIG. It is explanatory drawing which shows the arrangement | positioning space | interval of the soft foam resin introduction part which omitted the supporter material and looked at the side support part of FIG. 3 from the back side of the seat cushion pad. It is an enlarged view of the left side support part in FIG. It is explanatory drawing which shows the arrangement | positioning space | interval of the soft foam resin introduction part which omitted the supporter material and looked at the side support part of FIG. 5 from the back side of the seat cushion pad. It is an enlarged view of the left side support part in FIG. 2 which shows the specific shape of the soft foam resin introduction part when the soft foam resin introduction part is stepped. It is sectional drawing of the metal mold | die which shape | molds a seat cushion pad. It is an enlarged view of the side support part periphery of the right side of the metal mold | die shown in FIG. It is an enlarged view of the side support part periphery of the left side of the metal mold | die shown in FIG. It is a front view of the seat back pad concerning a 2nd embodiment of the present invention. FIG. 12 is a cross-sectional view taken along line II-II in FIG. FIG. 13 is an enlarged view of the upper part of FIG. It is explanatory drawing which shows the arrangement | positioning space | interval of the soft foam resin introduction part which abbreviate | omitted the supporter material and was seen from the cavity part side of the seat back pad. It is sectional drawing of the metal mold | die for seat back pad shaping | molding.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a plan view of a seat cushion pad as a first embodiment of the seat pad of the present invention. In addition, the code | symbol 1 in a figure shows the seat cushion pad of 1st Embodiment. 2 is a cross-sectional view taken along the line II of FIG. In addition, the lower side in FIG. 2 shows the back side of a seat cushion pad. FIG. 3 is an enlarged view of the right side support portion in FIG. FIG. 4 is an explanatory view of the side support portion of FIG. 3 as viewed from the back side of the seat cushion pad with the supporter material omitted in order to explain the arrangement interval of the soft foam resin introduction portion. FIG. 5 is an enlarged view of the left side support portion in FIG. FIG. 6 is an explanatory view of the side support portion of FIG. 5 viewed from the back side of the seat cushion pad with the supporter material omitted in order to explain the arrangement interval of the soft foam resin introduction portion.

  The seat cushion pad 1 has a thigh lower part 2, a bottom part 3, and left and right side support parts 4. On the upper surface of the seat cushion pad 1, a front and rear direction hanging groove 5 and a width direction hanging groove 6 for hanging a skin material (not shown) are provided so as to have an H shape. .

  The seat cushion pad 1 is provided on the back surface of the seat cushion pad body 10, another member 20 provided on the back surface of the right side support part 4 of the seat cushion pad body 10, and the left side support part 4 of the seat cushion pad body 10. The support member 30 that covers the provided separate member 25, at least a part of the back side of the seat cushion pad main body 10 and at least a part of each of the separate members 20, 25, and both the support member 30 and the separate member 20 are in contact with each other. A soft foam resin introduction portion 40 and a soft foam resin introduction portion 41 in contact with both the supporter material 30 and the separate member 25 are provided.

  A separate member 20 and a separate member 25 are provided on the back surface side of the side support portion 4, and the back surfaces of the separate member 20 and the separate member 25 are covered with a supporter material 30 made of a sheet-like nonwoven fabric. The supporter material 30 also covers portions of the back surface of the seat pad main body 10 that are adjacent to the separate member 20 and the separate member 25. Thus, because the back surface side of the separate member 20 and the separate member 25 where the seat frame or the like is disposed is covered with the supporter material 30, the separate member 20 and the separate member 25 and the seat frame or the like are not in direct sliding contact, As a result, occurrence of abnormal noise can be prevented.

  As shown in FIG. 3, a recess 21 is provided on the back side of the separate member 20, and the supporter material 30 is along the surface of the recess 21. That is, the supporter material 30 overlaps both the side surface and the bottom surface of the recess 21. A hole for inserting a later-described protrusion 57 may be provided on the bottom surface of the recess 21. The protrusion 57 may be inserted into the separate member 20 without providing a hole.

  As shown in FIG. 5, a recess 26 is provided on the back side of the separate member 25, and the supporter material 30 is along the surface of the recess 26. That is, the supporter material 30 overlaps both the side surface and the bottom surface of the recess 26. A hole for inserting a projection 59 described later may be provided on the bottom surface of the recess 26. The protrusion 59 may be inserted into the separate member 25 without providing a hole.

The seat cushion pad body 10 is made of polyurethane foam. The separate member 20 and the separate member 25 are made of expanded polystyrene, expanded polyethylene, or the like. In this embodiment, expanded polystyrene (expanded polystyrene) is used. The supporter material 30 is preferably a nonwoven fabric made of at least one raw material selected from polypropylene, polyethylene, polyethylene terephthalate, acrylic, wool, rayon, and polyester having a basis weight of 10 to 300 g / m ² . The thickness of the supporter material 30 is preferably in the range of 0.2 to 1.0 mm, and more preferably in the range of 0.4 to 0.6 mm.

  Here, when the seat cushion pad main body 10, the separate member 20, and the supporter material 30 are the above materials, the adhesion between the seat cushion pad main body 10 and the separate member 20 is good, but the separate member 20 and the supporter material 30 Does not adhere to. Therefore, by providing the introduction portion 40 made of a polyurethane foam locally introduced into the separate member 20, the supporter material 30 in the portion along the separate member 20 is bonded to the introduction portions 40a, 40b, and 40c, and the separate member 20 is also The support member 30 is fixed to the separate member 20 because it is bonded to the introduction portions 40a, 40b, and 40c. When the introduction portion 40 is not present, the supporter material 30 has no means for fixing the supporter material 30 to the separate member 20 between the portion 31a away from the seat cushion pad main body 10 and the end portion 31b. Hangs down in a bag shape between the part 31a and the part 31b.

  Since the introduction portion 40 made of polyurethane foam serves to fix the supporter material 30 to the separate member 20 as described above, it does not need to be provided on the entire surface between the separate member 20 and the supporter material 30, and locally It may be provided. In addition, when the introduction portion 40 is locally provided between the separate member 20 and the supporter material 30, when the seat cushion pad 1 is formed, the surface where the introduction portion 40 is not provided is formed via the supporter material 30. It is necessary to position and arrange the separate member 20 on the molding die by bringing it into contact with the surface of the die.

  Next, the arrangement interval and size of the introduction portion 40 will be described with reference to FIG. In FIG. 4, three introduction portions 40a, 40b, and 40c are shown, but the number is not limited to this. The introduction portions 40a to 40c are formed in a rod shape so as to contact both the separate member 20 and the supporter material 30. The size of each of the introduction portions 40a to 40c is preferably a cube or a rectangular parallelepiped having a side length of 10 mm or more, but each side does not necessarily have to be a straight line, and each angle does not necessarily have to be a right angle. .

  Further, the introduction portion 40 may be formed so as to surround the recesses 21a and 21c as shown in the introduction portions 40a and 40b in FIG. 4, or may be formed without including the recess 21 as shown in the introduction portion 40c. May be. Here, for example, since the recess 21a is surrounded by the introduction portion 40a, the support material 30 is bonded to the introduction portion 40a, that is, a part of the polyurethane foam on the side surface of the recess 21a. This is preferable in that the support material 30 does not peel in the recess 21a as compared to the recess 21b not surrounded by the portion 40.

  And the introduction parts 40a-40c are arrange | positioned by the space | interval of the distance L1 in FIG. If the distance L1 is determined so that the total area of the portions in contact with the supporter material 30 for each of the introduction portions 40a to 40c is in the range of 5 to 95% with respect to the area where the supporter material 30 covers the separate member 20 good. Further, the distance L1 does not need to be constant. For example, the interval between the introduction portion 40a and the introduction portion 40b and the interval between the introduction portion 40b and the introduction portion 40c may be different. In the first embodiment, the total area of the portions in contact with the supporter material 30 for each of the introduction portions 40 a to 40 c is 20% with respect to the area where the supporter material 30 covers the separate member 20.

  Further, when the seat cushion pad main body 10, the separate member 25 and the supporter material 30 are made of the above materials, the adhesion between the seat cushion pad main body 10 and the separate member 25 is good, but the separate member 25 and the supporter material 30 Does not adhere. Therefore, by providing the introduction portion 41 made of polyurethane foam locally introduced into the separate member 25, the supporter material 30 in the portion along the separate member 25 is bonded to the introduction portions 41a, 41b, 41c, 41d, 41e, and 41f. The separate member 25 is also bonded to the introduction portions 41a, 41b, 41c, 41d, 41e, and 41f, so that the supporter material 30 is fixed to the separate member 25. When the introduction portion 41 is not present, the supporter material 30 has no means for fixing the supporter material 30 to the separate member 25 between the portion 32b away from the seat cushion pad main body 10 and the end portion 32a. Hangs down in a bag shape between the region 32a and the region 32b.

  Since the introduction portion 41 made of polyurethane foam serves to fix the supporter material 30 to the separate member 25 as described above, the introduction portion 41 does not need to be provided on the entire surface between the separate member 25 and the supporter material 30. It may be provided. In addition, the introduction portion 41 is locally provided between the separate member 25 and the supporter material 30 when the seat cushion pad 1 is formed, the surface on which the introduction portion 41 is not provided is formed via the supporter material 30. This is necessary for positioning and disposing the separate member 25 on the molding die by bringing it into contact with the surface of the die.

  Next, the arrangement interval and size of the introduction portion 41 will be described with reference to FIG. In FIG. 6, six introduction portions 41a, 41b, 41c, 41d, 41e, and 41f are shown, but the present invention is not limited to this. The introduction portions 41 a to 41 f are formed in a wedge shape toward the inside of the separate member 25 on both sides of the rear side end surface of the separate member 25. The individual sizes of the introduction portions 41a to 41f are preferably wedge shapes in which the length of one side is 10 mm or more, but each side is not necessarily a straight line. Further, the introduction portions 41a to 41f may have a step shape as shown in FIG. 7 in addition to the wedge shape.

  Further, the introduction portion 41 may be formed so as to contact the recesses 26a and 26b as shown by the introduction portions 41a, 41b and 41c and 41d in FIG. 6, or the recess 26c as shown by the introduction portions 41e and 41f. You may form so that it may not contact. Here, for example, since the recess 26a is in contact with the introduction portion 41a, the support material 30 is bonded to the introduction portion 41a, that is, a part of the polyurethane foam, on the side surface of the recess 26a. This is preferable in that the supporter material 30 does not peel in the recess 26a compared to the recess 26c that does not contact 41c.

  And the introduction parts 41a-41f are arrange | positioned by the space | interval of the distance L2 in FIG. If the distance L2 is determined so that the total area of the portions in contact with the supporter material 30 for each of the introduction portions 41a to 41f is in the range of 5 to 95% with respect to the area where the supporter material 30 covers the separate member 25 good. Further, the distance L2 does not need to be constant. For example, the interval between the introduction portion 41a and the introduction portion 41c and the interval between the introduction portion 41c and the introduction portion 41e may be different. In the first embodiment, the total area of the portions in contact with the supporter material 30 for each of the introduction portions 41 a to 40 f is 5% with respect to the area where the supporter material 30 covers the separate member 25.

  Next, a mold for forming the seat cushion pad 1 will be described. 8 is a cross-sectional view of a mold for molding the seat cushion pad 1, and FIG. 9 is an enlarged view of the periphery of the right side support portion of the mold shown in FIG. FIG. 10 is an enlarged view around the left side support part of the mold shown in FIG.

  The mold 50 has an upper mold 51 and a lower mold 52. From the lower mold 52, a ridge 53 for forming the suspending groove 5 and a ridge (not shown) for forming the suspending groove 6 are erected. Between the ridges 53 is a cavity part 54 for forming the thigh lower part 2 and the bottom part 3, and outside the ridges 53 is a cavity part 55 for forming the side support part 4.

  As a holding means for holding the separate member 20, as shown in FIG. 9, a pedestal portion 56 is provided on a mold ceiling surface facing the cavity portion 55 of the upper mold 51, and the pedestal portion 56 is provided below the pedestal portion 56. A protrusion 57 is provided. The projection 57 has a narrow neck portion on the base end side (the pedestal portion 56 side), and the lower side from the neck portion gradually increases in diameter to become the maximum diameter portion, and the lower side from the maximum diameter portion is the tip. It has a pointed shape in which the diameter decreases toward the (lower end).

  As a holding means for holding the separate member 25, similarly, as shown in FIG. 10, a pedestal portion 58 is provided on the die ceiling surface of the upper mold 51 facing the cavity portion 55, and this pedestal portion 58 is provided. A projection 59 is provided so as to project downward from the projection. The projection 59 has a narrow neck portion on the base end side (the pedestal portion 58 side), and the diameter gradually increases from the neck portion to the lower side to become the maximum diameter portion. It has a pointed shape in which the diameter decreases toward the (lower end).

  In order to perform foam molding of the seat cushion pad 1, first, the supporter material 30 is disposed along the lower surface of the upper mold 51 and temporarily fixed with a double-sided tape or the like. It should be noted that magnetic fibers are mixed into the supporter material 30 or a magnetic piece such as a wire is fastened to the supporter material 30 with a tape or the like, and a magnet is provided on the upper mold 51 so that the periphery of the supporter material 30 is The upper mold 51 may be magnetically attracted and held.

  Next, the separate member 20 is attached to the upper mold 51. At this time, the pedestal 56 is fitted into the recess 21 and the protrusion 57 is inserted into the separate member 20. Similarly, the separate member 25 is attached to the upper mold 51. At this time, the pedestal 58 is fitted into the recess 26 and the protrusion 59 is inserted into the separate member 25. As described above, a hole for engaging the protrusion 57 may be provided on the bottom surface of the concave portion 21, and a hole for engaging the protrusion 59 may be provided on the bottom surface of the concave portion 26. In addition, the protrusions 59 may be inserted into the separate members 25, respectively.

  Thereafter, the urethane stock solution is supplied into the lower mold 52, the mold is closed, and the urethane is heated and foamed. The urethane stock solution flows from the portions 42a and 42b shown in FIG. 9 into the grooves and through holes provided in the separate member 20 to form the introduction portion 40a. The same applies to the introduction portions 40b to 40c. Further, the urethane stock solution flows from the portion 43a and the portion 43b shown in FIG. 10 into the chamfered portion provided in the separate member 25 to form the introduction portions 41a and 41b. The same applies to the introduction portions 41c to 41f. Then, after foaming, it is cured, the mold is opened, and the mold is removed. The separate member 20, the separate member 25, and the supporter material 30 are integrated with the seat pad main body 10 made of a foam molded product, and are smoothly released from the upper mold 51. A crush process may be performed after demolding.

  In the cushion pad 1 manufactured in this way, since the separate member 20 is covered with the supporter material 30, the generation of abnormal noise due to the sliding contact between the separate member 20 and the seat frame or the like is prevented. Further, since the separate member 25 is similarly covered with the supporter material 30, the generation of abnormal noise due to the sliding contact between the separate member 25 and the seat frame or the like is prevented. Further, since the separate member 20 and the separate member 25 are formed in advance, the support member 30 is not impregnated with the resin from the separate member 20 and the separate member 25 when the cushion pad 1 is foam-molded. Generation of abnormal noise due to sliding contact with the frame or the like is also prevented.

  Further, since the supporter material 30 is fixed at the introduction portion 40 along the separate member 20, the supporter material 30 does not hang down in the form of a bag between the part 31a and the part 31b. Since the introduction portion 41 is fixed along the separate member 25, the supporter material 30 does not hang down in a bag shape between the portion 32a and the portion 32b. Therefore, in the operation of attaching the seat cushion pad 1 to the seat frame, the supporter material 30 is not damaged by hooking the hanging portion of the supporter material 30 onto the seat frame components.

  In the first embodiment, since the separate member 20 and the separate member 25 are made of foamed polystyrene that is lighter than polyurethane foam, the weight of the cushion pad 1 can be reduced.

  In addition, since the polystyrene foam is lighter and higher in hardness than polyurethane foam, the hardness of the side support portion 4 can be increased.

  In the first embodiment, since a sheet-like material such as a nonwoven fabric is used as the supporter material 30, the supporter material 30 can be easily disposed along the upper mold 51. Further, since the supporter material 30 is sandwiched between the separate member 20 and the upper mold 51 when the seat pad body 10 is foam-molded, the supporter material 30 is prevented from being displaced. Similarly, since the supporter material 30 is sandwiched between the separate member 25 and the upper mold 51 when the seat pad main body 10 is foamed, the supporter material 30 is prevented from being displaced.

  In the first embodiment, as shown in FIG. 2, the recessed shape portion 7 facing the separate member 20 is provided on the back side of the cushion pad 1, and the seat frame is fitted therewith. Misalignment with the seat frame or the like is prevented. Then, by engaging the concave portion 21 of the separate member 20 with the pedestal portion 56 of the upper mold 51, the positional shift of the separate member 20 during the molding is prevented. Similarly, the recessed portion 8 facing the separate member 25 is provided on the back side of the cushion pad 1 so that the seat frame is fitted therewith, so that the misalignment between the separate member 25 and the seat frame is prevented. Is done. Then, by engaging the concave portion 26 of the separate member 25 with the pedestal portion 58 of the upper mold 51, the displacement of the separate member 25 during the molding is prevented.

  In the first embodiment, the separate member 20 can be firmly held by the upper mold 51 by pushing the protrusion 57 into engagement with the bottom surface of the recess 21. Similarly, the separate member 25 can be securely held by the upper mold 51 by pushing the protrusion 59 into engagement with the bottom surface of the recess 26.

  Next, a second embodiment of the seat pad of the present invention will be described. FIG. 11 is a front view of the seat back pad according to the second embodiment. Reference numeral 60 in the figure denotes a seat back pad according to the second embodiment. 12 is a cross-sectional view taken along the line II-II in FIG. 11, and FIG. 13 is an enlarged view of the upper part of FIG.

  The seat back pad 60 includes a seat back pad main body 61, a separate member 62 provided on the back side of the seat back pad main body 61, at least a part of the back side of the seat back pad main body 61, and at least the separate member 62. It has a supporter material 64 that covers a part, and an introduction portion 65 that contacts both the supporter material 64 and the separate member 62.

The seat back pad main body 61 is made of polyurethane foam. The separate member 62 is made of foamed polystyrene, foamed polyethylene, or the like. In this embodiment, foamed polystyrene (foamed polystyrene) is used. The supporter material 64 is preferably a non-woven fabric made of at least one raw material selected from polypropylene, polyethylene, polyethylene terephthalate, acrylic, wool, rayon and polyester having a basis weight of 10 to 300 g / m ² . The thickness of the supporter material 64 is preferably in the range of 0.2 to 1.0 mm, and more preferably in the range of 0.4 to 0.6 mm.

  As shown in FIG. 12, the seat back pad main body 61 has a front surface 66a and a back surface 66b, and also has a front side portion 67a and a back side portion 67b. And the upper edge and the left and right side edges project toward the center on the back side and are opened toward the center on the back side of the seat back pad main body 61. A hollow portion (concave shape portion) 63 is formed. The separate member 62 has a substantially inverted J-shaped cross section that faces the cavity 63 and wraps around the cavity 63.

  The surface of the separate member 62 facing the cavity 63 is covered with a supporter material 64 (see FIG. 13). The supporter material 64 also covers a portion of the seat back pad main body 61 adjacent to the supporter material 64.

  Here, the main body 61 and the separate member 62 of the seat back pad 60 have a bent portion 68 located at the back of the cavity 63, and the bent portion 68 is not particularly fixed to the separate member 62, and the supporter material 64. Is a portion that tends to sag in a bag shape. Therefore, the bent portion 68 of the separate member 62 is provided with an introduction portion 65 made of polyurethane foam. Since the introduction portion 65 serves to fix the supporter material 64 to the separate member 62, the introduction portion 65 does not need to be provided on the entire surface between the bent portion 68 of the separate member 62 and the supporter material 64, and is provided locally. It ’s fine. Further, providing the introduction portion 65 locally between the bent portion 68 of the separate member 62 and the supporter material 64 means that when the seat back pad 60 is formed, the surface where the introduction portion 65 is not provided is the supporter material 64. It is necessary to position and arrange the separate member 62 on the molding die by abutting against the surface of the molding die (core) via.

  Next, the arrangement interval and size of the introduction portion 65 made of polyurethane foam will be described. FIG. 14 is an explanatory view in which the support material 64 is omitted and the seat back pad 60 is viewed from the cavity 63 side in order to explain the arrangement interval of the introduction portions 65. FIG.

  In FIG. 14, three cylindrical introduction portions 65a, 65b, and 65c are shown, but the present invention is not limited to this. The size of each of the introduction parts 65a to 65c is preferably such that the diameter of the bottom surface of the cylinder is 10 mm or more. When the bottom surface is not circular, such as a quadrangular prism, the area of the bottom surface is the area of a circle with a diameter of 10 mm. The above is preferable. Further, the introduction portions 65a to 65c are arranged at an interval of a distance L3 in FIG. The distance L3 is determined so that the total area of the portions in contact with the supporter material 64 for each of the introduction portions 65a to 65c is in the range of 5 to 95% with respect to the area where the supporter material 64 covers the separate member 62. It ’s fine. Further, the distance L3 does not need to be constant. For example, the interval between the introduction portion 65a and the introduction portion 65b may be different from the interval between the introduction portion 65b and the introduction portion 65c. In addition, in 2nd Embodiment, the sum total of the area of the part which touches the supporter material 64 about each of the introduction parts 65a-65c of the separate member 62 is 40% with respect to the area which the supporter material 64 covers the separate member 62. .

  Next, a method for forming the seat back pad 60 will be described. FIG. 15 is a cross-sectional view of a molding die for the seat back pad 60. A mold 70 for molding the seat back pad 60 includes an upper mold 71, a lower mold 72, and a core 73. The core 73 is attached to the upper mold 71. The peripheral edge portion of the core 73 protrudes in the cavity portion 74 so as to form a cavity portion 63 in the seat back pad 60, and another member 62 is attached to the core 73 so as to strongly hold the protruding portion. Is retained.

  In order to perform foam molding of the seat back pad 60, first, the supporter material 74 is disposed along the core 73 and temporarily fixed.

  Next, the separate member 62 is attached to the core 73. At this time, the separate member 62 holds the peripheral edge portion of the core 73 by its own elastic force and is held by the core 73.

  Thereafter, the urethane stock solution is supplied into the lower mold 72, the mold is closed, and the urethane is heated and foamed. The urethane stock solution flows into the through hole formed in the separate member 62 in order to form the introduction portion 65 from the portion 69 shown in FIG. After foaming, cure, open mold, and demold. The separate member 62 and the supporter material 64 are integrated with the seat back pad main body 61 made of a foam molded product, and are smoothly released from the core 73. A crush process may be performed after demolding.

  In the seat back pad 60 manufactured in this way, the separate member 62 is covered with the supporter material 64, so that the generation of noise due to the sliding contact between the separate member 62 and the seat frame or the like is prevented. Further, since the separate member 62 is pre-molded, the support member 64 is not impregnated with resin from the separate member 62 during foam molding of the seat back pad 60, and the support member 64 is slidably contacted with the seat frame or the like. Generation of abnormal noise is also prevented. Further, since the supporter material 64 is sandwiched between the separate member 62 and the core 63 at the time of foam molding of the seat back pad main body 61, the shift of the supporter material 64 is prevented.

  In addition, the support member 64 is separated by the introduction portion 65 even in the vicinity of the bag-like cavity 63, particularly the bent portion 68, in which the end portion of the supporter material 64 is wavy and the bag-like sagging of the supporter material 64 is likely to occur. Since the support member 64 is fixed to the member 62, the supporter material 64 does not hang down in a bag shape or undulate.

  In the second embodiment, since the separate member 62 can be easily held by causing strong interference with the core 73, the molding operation is easy.

  In addition, the place mentioned above only illustrated embodiment of this invention, and this invention can add a various change within the description range of a claim. For example, the disposition position of the separate member may be the bottom of the butt or the pelvis support. Moreover, you may hold | maintain another member only by a base part, without providing a protrusion in an upper mold | type.

  According to the present invention, since the separate member and the seat frame or the like are in sliding contact with each other via the supporter material, the generation of abnormal noise can be prevented, and the supporter material that does not adhere to the separate member Since the supporter material can be fixed at the soft foam resin introduction portion by locally providing the soft foam resin introduction portion in contact with both of the separate members at at least one location of the separate member, the end portion of the support material When the seat pad is attached to the seat frame, etc., the wavy portion of the support material or the portion that hangs down in the bag shape is hung on the seat frame parts, etc. It is possible to prevent the material from being damaged. In addition, since the soft foam resin introduction portion is locally provided, when the seat pad is molded, the portion where the soft foam resin introduction portion is not provided is provided with a supporter material on the surface of the seat pad molding die. Therefore, the separate member can be positioned inside the molding die, and the separate member can be embedded in the back surface side of the seat pad main body with high accuracy.

1 Seat cushion pad
2 Lower thigh
3 Bottom of bottom
4 Side support part
5 Front / rear hanging groove
6 Suspension groove in the width direction
7, 8 Recessed shape
10 Seat cushion pad body
20, 25 Separate parts
21, 21a, 21b, 21c, 21d recess
26, 26a, 26b, 26c Recess
30 Supporter material
31a, 31b, 32a, 32b site
40, 40a, 40b, 40c Soft foam resin introduction part
41, 41a, 41b, 41c, 41d, 41e, 41f Soft foam resin introduction part
42a, 42b, 43a, 43b site
50 molds
51 Upper mold
52 Lower mold
53 ridges
54, 55 Cavity
56, 58 pedestal
57, 59 protrusion
60 Seat back pad
61 Seat back pad body
62 Separate parts
63 cavity
64 Supporter material
65, 65a, 65b, 65c Soft foam resin introduction part
66a surface
66b reverse side
67a Front part
67b Rear side
68 Bend
70 mold
71 Upper mold
72 Lower mold
73 core

Claims (4)

A seat pad body made of a soft foam resin;
Another member disposed on the back side of the seat pad body;
A supporter material covering at least a part of the back side of the seat pad body and at least a part of the separate member;
With
The seat pad, wherein the separate member locally has at least one soft foamed resin introduction portion in contact with both the supporter material and the separate member.   The seat pad according to claim 1, wherein the separate member is a molded body by bead foaming.   The area of the part which contacts the said supporter material of the said soft foamed resin introduction part is 5-95% with respect to the area which the said supporter material covers the said another member, The Claim 1 or 2 characterized by the above-mentioned. Seat pad.   The seat pad body made of the soft foamed resin has a front side portion and a back side portion, and the back side portion has an upper edge portion and left and right side edge portions. The side edge portion projects toward the center of the rear side portion to form a bag-like cavity that opens toward the center on the back side of the seat pad body. The seat pad of any one of -3.

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