JP2012080909A - Method of manufacturing seat pad containing duct and foaming mold used in the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a seat pad containing a duct for preventing a forming raw material from entering the inside of a duct from an air outlet when integrally form-molding the seat pad.SOLUTION: In the method of manufacturing a seat pad containing a duct, an air distribution duct 6 including the air outlet 64 is set to a forming mold 7, the sheet pad 1 is form-molded after injection of the foaming raw material (m) and mold closing, and a recess 21 formed on a sheet pad surface 1a is fitted to the air outlet 64 as an air blow out port 20. A cave 721 is dug down in a raised section 72 of which the recess 21 is formed, the forming mold 7 of which a leaf spring body 8 including two opposing plate piece sections 8b is arranged inside the cave 721 is used, the two plate piece sections 8b narrow an interval to enter the inside of the duct 6 from the air outlet 64 in setting of the duct 6 to the forming mold 7 and further are spread by elastic restoration to adhere a duct section 66 around the air outlet 64 to an upper surface portion 722 of the raised section around the cave 721, and then the sheet pad 1 is integrally form-molded after the injection of the forming raw material (m) and the mold closing.

Description

  The present invention relates to a seat cushion seat pad constituting a vehicle seat and a method of manufacturing a duct-containing seat pad in which a duct is integrated by insert molding, and a foaming mold used for the method.

  Seat cushions that make up the seats and backrest of seats mounted on vehicles such as automobiles are the parts where the occupant sits down and touches directly. It may feel cold. For these reasons, seat seats have been proposed in which the temperature is adjusted by providing an air distribution duct inside the seat pad (for example, Patent Documents 1 to 3).

JP-A-3-297414 JP-A-2005-95343 JP 2005-287532 A

Patent Documents 1 to 3 disclose an invention in which a seat pad is integrally foamed by inserting a duct for air distribution. However, in both cases, there is a problem that the foaming material enters the duct from the air outlet during foam molding of the seat pad, but there is no description of this countermeasure. Patent Document 1 states that “the air ducts 18 and 19 are formed of pipes or the like corresponding to the shapes of the seat cushion 14 and the seat back 16, for example, and communicated with the air duct (air distribution duct according to the present invention). The air vents 30 (air jet ports according to the present invention) are provided to extend to the seat surface at a plurality of locations separated from each other by a predetermined distance. ”However, how to close the air vents, seat cushion 14, seat It is not disclosed whether to perform foam molding of the back 16. Patent Documents 2 and 3 also do not disclose how to perform foam molding by closing the vent hole.
When seat pads such as the seat cushion 14 and the seat back 16 are integrally foamed by embedding an air duct, the foaming raw material enters the duct by simply closing the air vent against the mold surface. The duct is not only floating at the time of setting, but a foaming raw material such as urethane foams, so that a force from below is applied, so that the entire duct easily floats. Since there is an increase in the foaming pressure at the time of foam molding, if the vent hole is not sufficiently blocked, the foam raw material enters the pipe from the vent hole at the time of foam molding. Even if the foaming material that has entered the pipe is removed by post-processing, it is after the formation of the seat pad, and the distance from the seat pad surface to the vent is difficult. If you can't get rid of it, you're forced to make the product defective. This is because if the hardened portion of the foaming raw material is left in the duct, the ventilation resistance is increased and it is not suitable for a seat pad with a duct that pursues comfort.

  The present invention solves the above problem, and when a duct for air distribution having an air outlet in the duct path is embedded and the seat pad is integrally foam-molded, the foaming material enters the duct from the air outlet. It is an object of the present invention to provide a ducted seat pad manufacturing method and a foaming mold used therefor, in which the yield can be prevented and the removal of the foaming raw material that has entered the pipe can be eliminated. To do.

In order to achieve the above object, the gist of the invention described in claim 1 is that an air introduction portion (61) and an air distribution duct (6) provided with an air outlet (64) in a duct path are provided. After setting the foaming mold (7) and then injecting the foaming raw material (m) and closing the mold, the seat pad (1) in which the duct (6) is embedded is foam-molded. A manufacturing method of a seat pad with a duct, wherein a recess (21) formed on a seat pad surface (1a) on the contact side is aligned with the air outlet (64) to form an air outlet (20), the recess (21 The cave (721) is dug down from the upper surface portion (722) of the raised portion (72) forming the ridge), and two opposing plate pieces (8b) are elastically projected into the cave (721). A set of the duct (6) to the foaming mold (7) using a foaming mold (7) provided with a leaf spring body (8) having the property of maintaining the opposing spacing, The plate pieces (8b) of the sheets To enter the duct (6) from the air outlet (64) so as to reduce the distance between the two, and further, the distance between the two plate pieces (8b) is expanded by elastic restoration, The duct portion (66) around the spout (64) is brought into close contact with the upper surface portion (722) of the raised portion around the cave (721), and then the foam (m) is injected and the mold is closed, and then the duct ( 6) is inserted, and the seat pad (1) is integrally foam-molded.
According to a second aspect of the present invention, there is provided a method of manufacturing a duct-padded seat pad according to the first aspect, wherein the air jet port (64) is provided on the duct surface portion (66a) of the duct portion (66) around the air jet port (64). An encircling annular recess (662) is further provided, and in the set of the duct (6) to the foaming mold (7), the ridge upper surface portion (722) closes the annular recess (662). It abuts on the surface portion (66a). According to a third aspect of the present invention, there is provided a method of manufacturing a ducted seat pad according to the first or second aspect, wherein an annular groove (723) is further formed in the upper surface portion (722) of the raised portion around the cave (721), In the set of the duct (6) to (7), the duct surface portion (66a) related to the duct portion (66) around the air jet port (64) is closed so as to block the annular groove (723). It is characterized by contacting the upper surface portion (722) of the raised portion.
The gist of the invention described in claim 4 is that the air distribution duct (6) provided with the air introduction part (61) and the air outlet (64) in the duct path is set in the foaming mold (7). Then, through injection of foaming raw material (m) and mold closing, the seat pad (1) in which the duct (6) is embedded is foam-molded, and in the foam molding, the seat pad surface on the passenger contact side ( 1a) is a foaming mold used in a method for manufacturing a seat pad with a duct in which a recess (21) formed in the air outlet (64) is formed in accordance with the air outlet (64), the recess (21) being A cave (721) is dug from the upper surface portion (722) of the raised portion (72) to be formed, and two opposing plate pieces (8b) are elastic in the cave (721). And a plate spring body (8) that maintains a spacing between each other, and the set of the duct (6), the two pieces of plate pieces (8b) are arranged so as to close each other. Air eruption The duct (6) enters the duct (6) from the opening (64), and further expands the distance packed with the two plate pieces (8b) by elastic recovery, the duct portion around the air outlet (64) ( 66) is in a foaming mold used in a method for manufacturing a ducted seat pad, characterized in that it is closely attached to the upper surface portion (722) of the raised portion around the opening of the cave (721).

  The manufacturing method of a duct-filled seat pad of the present invention and the foaming mold used therefor can prevent the foaming material from entering the duct from the air outlet during foaming of the seat pad, and improve the yield and work efficiency and production. It exhibits excellent effects such as improving the performance and contributing to quality improvement.

In Embodiment 1, it is the whole perspective view seen from the surface side of a seat pad with a duct which expresses a seat pad with a dashed-two dotted line. It is the whole perspective view which looked at the sheet pad with a duct from the angle different from FIG. It is the III-III arrow directional view of FIG. FIG. 3 is an explanatory cross-sectional view in which a duct for air distribution and a nonwoven fabric are set in a foaming mold and a foaming material is injected. FIG. 5 is a view taken in the direction of arrows V-V in FIG. 4. It is the elements on larger scale of FIG. FIG. 5 is an explanatory sectional view proceeding from FIG. 4 to a mold closing step. FIG. 6 is an explanatory sectional view of another embodiment instead of FIG. 5. In Embodiment 2, it is explanatory sectional drawing which set the duct to the foaming type | mold. It is explanatory sectional drawing which concerns on the setting progress of the duct to a foaming type.

Hereafter, the manufacturing method of the sheet pad with a duct concerning this invention and the foaming type used for this are explained in full detail.
(1) Embodiment 1
1 to 8 are a manufacturing method of a duct-padded seat pad according to the present invention and a foaming mold used therein, and FIG. 1 is an overall perspective view of the seat pad represented by a two-dot chain line as viewed from the surface side. 2 is an overall perspective view of the seat pad with ducts as seen from a different angle, FIG. 3 is a view taken along the line III-III in FIG. 2, and FIG. 5 is a sectional view taken along the line VV in FIG. 4, FIG. 6 is a partially enlarged view of FIG. 5, FIG. 7 is an explanatory sectional view proceeding from FIG. 4 to the mold closing process, and FIG. An alternative embodiment diagram is shown. 5 to 8 do not show the hatching of the leaf spring body. Moreover, although the tongue-like clip 67 and the attachment hole 671 as shown in FIG. 1 are provided in the duct 6, illustration of those is abbreviate | omitted in other figures.

  The manufacturing method of the seat pad with a duct uses the foaming mold 7 to set the air distribution duct 6 (hereinafter simply referred to as “duct”) in the foaming mold 7, and then inject the foaming raw material m and close the mold. Then, the seat pad 1 as shown in FIGS. 1 to 3 is foam-molded. The seat pad 1 with the duct 6 is used for a seat portion of a vehicle seat and a seat cushion of a backrest. Here, it applies to the seat pad 1 with the duct 6 for the seat part for vehicle seats. Prior to foam molding, a duct 6 and a foam mold 7 are prepared.

  The duct 6 is a resin tubular member made of polypropylene resin or the like. The duct 6 is provided with an air introduction portion 61 and an air outlet 64 in the duct path. This embodiment is a blow-molded duct 6 having a substantially H-shaped air distribution channel 60 in plan view as shown in FIGS. 1 and 3, and a pair of vertical cylindrical portions from both ends of a horizontal cylindrical portion 6b arranged in the vehicle width direction. 6a extends in the vehicle front-rear direction.

A plurality of air jets 64 are opened on the surface side of the duct 6. The “surface side” of the present invention refers to the side of the surface that comes into contact when an occupant sits on a seat. Here, the duct 6 is provided with a plurality of nozzle portions 65 for air jets 64 made of short pipes on the surface side.
The duct portion 66 around the air outlet 64 is not circular in cross section, but has an oval shape that is flattened as shown in FIG. The duct surface portion 66a related to the duct portion 66 is formed in a substantially flat surface, and the duct back surface portion 66b facing the duct surface portion 66a via the flow path 60 also forms a flat surface, and both are formed in an arc surface shape. The duct side surface portion 66c is connected. As shown in FIGS. 1 and 5, the duct surface portion 66 a is formed with an annular recess 662 that is recessed in a narrow ring groove shape around the air outlet 64 and surrounds the air outlet 64. As shown in FIG. 1, the annular recess 662 is limited to the four locations of the air jets 64 located at the four corners of the vertical cylindrical portion 6 a, but can be provided at all the air jets 64. In the present embodiment, not only the duct surface portion 66a and the duct back surface portion 66b related to the duct portion 66 around the air jet port 64 are formed on a flat surface, but the surface side of the duct vertical tube portion 6a and the horizontal tube portion 6b. Thus, almost the entire back side is formed on a flat surface as shown in FIG.

On the other hand, an air introduction portion 61 is provided on the back side of the duct 6. When the seat pad 1 with the duct 6 is completed by foam molding of the seat pad 1, the air introduction part 61 whose front end opening becomes the air introduction opening e protrudes from the substantially center of the seat pad back surface 1b (FIG. 3). Specifically, the bulge portion 6b ₁ at substantially the center of the horizontal tubular portion 6b is overhanging (FIG. 1), bent to the back surface side bulging portion 6b ₁ at its distal end, it is extended form the air inlet e It becomes the cylindrical air introduction part 61 which does. The air introduction part 61 stands up with respect to the main part of the duct 6 on substantially the same plane.

The foaming mold 7 used in the manufacturing method of the seat pad with duct is a split mold as shown in FIG. 4 and includes a lower mold 7a (one split mold) and an upper mold 7b (other split mold). The lower mold 7a and the upper mold 7b are connected so as to be openable and closable by a hinge (not shown). When the mold is closed as shown in FIG. 7 using the hinge as a fulcrum, the mold surface 71 of the lower mold 7a having a large degree of dents as a whole and the mold surface 76 of the substantially flat upper mold 7b having a recess 73 in part. Then, the cavity 70 of the seat pad 1 with the duct 6 is formed. 1 to 7, the seat pad surface 1a side is formed by the mold surface 71 of the lower mold 7a, and the seat pad back surface 1b side is molded by the mold surface 76 of the upper mold 7b (FIGS. 4 and 7). .
In the lower mold 7a, the mold surface for the upper half part of the main part 2 is centered, and the mold surface for the upper half part of the side part 3 is formed on both sides thereof. The lower mold 7a is provided with a plurality of raised portions 72 for forming the respective depressions 21 by raising each part of the main part mold surface 71a in a columnar shape. Each raised portion 72 is responsible for forming the recess 21, and the upper portion 72 a further serves to seal the air outlet 64. A cave 721 is dug into a mortar shape from the upper surface portion 722 of each raised portion 72. A flat and smooth surface is formed around the cave 721 and an upper surface portion 722 surrounding the cave is provided. A flat bottom surface 721 b is formed at the bottom of the cave 721. Then, the leaf spring body 8 is attached to the bottom surface 721b.

  The leaf spring body 8 is a metal thin plate body that is disposed in the cave 721 and has two opposing plate pieces 8b that are elastic and maintain a mutual facing distance (inside the circle in FIG. 7). Enlarged view). The leaf spring body 8 includes a rectangular bottom piece portion 8a that is placed substantially horizontally on the cave bottom surface 721b, and a pair of plate piece portions 8b that are bent and extend from opposite sides of the bottom piece portion 8a. The plate piece portion 8b has a lateral width that can pass through the air outlet 64 and the nozzle portion 65, and has a rectangular side view (FIG. 4). A small hole 80 is provided in the center of the bottom piece 8a, and the leaf spring body 8 is fixed to the cave bottom surface 721b with a screw pn using the small hole 80. The plate spring body 8 fixed to the cave bottom surface 721b has the upright portion 81 of the two plate pieces 8b extending upward from the bottom piece 8a above the cave opening 721a as shown in FIG. At the point where the tip protrudes slightly from the cave opening 721a, it bends outward. The two projecting portions 82 after being bent project from both sides substantially horizontally so as to move away from each other. In addition, you may project both the overhang | projection parts 82 toward both outward and a little upwards, respectively. By doing so, it becomes easy to take out the sheet pad with duct after molding from the foaming mold 7. Furthermore, at the tip of the overhanging portion 82, the light is refracted toward the center of the bottom piece 8a at an acute angle, and the guide portion 83 extends obliquely upward. Both guide portions 83 protrude above the cave 721 while reducing the distance from each other in a letter C shape when viewed from the front. Both plate pieces 8b are shaped so that the overhang of the overhang portion 82 is too large as it is, and cannot pass through the air outlet 64 and the nozzle portion 65 (FIG. 5). However, if both the plate piece portions 8b are elastically deformed so as to approach each other as shown by a chain line in FIG. 5, the guide portion 83 and the overhanging portion 82 of the plate piece portion 8b pass through the air outlet 64 and the nozzle portion 65. Can do. Since the elastic deformation of the plate piece portion 8b is released from the protruding portion 82 after passing through the air jet port 64 and the nozzle portion 65 and entering the duct 6, the duct inner surface 66d around the air jet port 64 is forced. Press on.

By providing the leaf spring body 8 in the cave 721 of the raised portion 72, when the duct 6 is set by aligning the air outlet 64 to the raised portion 72 of the foaming mold 7, the two plate pieces 8b are mutually connected. It enters into the duct 6 from the air jet port 64 so as to close the gap, and further, the distance where the two plate pieces 8b are packed is expanded by elastic restoration, and the duct portion 66 around the air jet port 64 is expanded. Is closely attached and sealed to the upper surface portion 722 of the raised portion around the cave 721 (FIG. 5).
Specifically, in the set of the duct 6 to the lower mold 7 a, the nozzle portion 65 is accommodated in the cave 721 around the raised portion 72, but only the nozzle portion 65 is placed on the cave 721 of the raised portion 72. The nozzle portion 65 around the air outlet 64 can be held by the guide portion 83 (dashed line in FIG. 5). However, by pressing the back side duct portion 66 of the nozzle portion 65 that can be held by the guide portion 83 on the cave 721 from above, the tip of the nozzle portion 65 forming the air ejection port 64 presses both the guide portions 83 and is elastic. The two guide portions 83 enter the nozzle portion 65 by deforming them so that they are brought close to each other (chain line in FIG. 5). The nozzle portion 65 moves toward the cave 721 while sliding down the surface of the guide portion 83 by the amount of the guide portion 83 that enters the nozzle portion 65. Thereafter, the nozzle portion 65 gets over the guide portion 83 and the overhang portion 82. At the same time, the two plate pieces 8b approaching due to elastic deformation are released, and the overhanging portion 82 that has entered the duct becomes the duct inner surface 66d around the air outlet 64, specifically, the base end of the nozzle portion 65. The surrounding duct inner surface 66d is pressed, and with this force, the duct portion 66 around the air jet port 64 is pressed against and closely sealed against the upper surface portion 722 of the raised portion around the cave 721 (solid line in FIG. 5).

In this way, the duct surface portion 66 a around the air outlet 64 abuts and closely contacts the raised portion upper surface portion 722 with the aid of the elastic restoring force of the leaf spring body 8, and the air outlet 64 accommodated in the cave 721. (FIGS. 5 and 7). The duct surface portion 66a around the air jet port 64 is in close contact with and sealed against the upper surface portion 722 of the raised portion around the cave 721, thereby eliminating the intrusion of the foam raw material m into the air jet port 64 by foam molding after mold closing. It has a mold structure.
When the seat pad 1 is formed, the raised portion 72 forms a recess 21 on the seat pad surface 1 a on the passenger contact side, and the recess 21 creates an air outlet 20 that communicates with the air outlet 64. 4-7, the code | symbol 661 is the step part by the side of the duct inner surface accompanying formation of the annular recess 662, the code | symbol 74 is a hollow which the mold | die closed and the air introduction part 61 contact | abuts, and the code | symbol 79 is the hanging groove 41 (vertical groove 41a). ) Is shown.

Using the foaming mold 7 and the duct 6, the seat pad 1 with the duct 6 is manufactured, for example, as follows.
First, the foaming mold 7 is set to the mold open state of FIG. The duct 6 in which the air introduction part 61 is provided and the air ejection port 64 is provided in the duct path is set in the lower mold 7a in the mold open state. Each nozzle portion 65 is accommodated in the cave 721 toward the lower side, and the duct 6 is set in the lower mold 7a so that the duct surface portion 66a around the air jet port 64 abuts on the upper surface portion 722 of the raised portion around the cave 721. To do.

  When the nozzle portion 65 is accommodated in the cave 721, the guide portion 83 of the leaf spring body 8 disposed in the cave 721 protrudes and protrudes above the cave 721, and the duct 6 is simply placed on the lower mold 7a. Then, the nozzle portion 65 can be held by the guide portion 83. The duct 6 is in a state of floating from the raised portion 72 while the tip portion of the nozzle portion 65 covers the guide portion 83 and accommodates a part thereof (dashed line in FIG. 5). Therefore, the duct 6 is placed on the lower mold 7 a so that the air jet port 64 of the nozzle portion 65 faces the guide portion 83 in the cave 721, and a part of the guide portion 83 is taken into the nozzle portion 65. After that, by pressing the back side duct portion 66 of the nozzle portion 65 toward the raised portion 72 by hand or the like, the nozzle portion 65 and the air jet port 64 are accommodated in the cave 721 and the duct 6 is set. .

  When the back side duct portion 66 of the nozzle portion 65 is pressed toward the leaf spring body 8, the guide portion 83 and the standing portion 81 receive this pressure and elastically deform in a direction approaching each other to absorb energy (see FIG. 5 chain line). The nozzle portion 65 slides down the surfaces of the guide portions 83 whose widths are narrowed due to elastic deformation, gets over the guide portions 83 and the overhang portions 82, and is accommodated in the cave 721. On the other hand, the guide portion 83 and the overhang portion 82 pass through the nozzle portion 65 and enter the duct, thereby being released from the restriction of the nozzle portion 65 and releasing the energy absorbed by the elastic deformation. 66, the inner peripheral surface 66d of the air outlet, that is, the duct inner surface 66d around the base end of the nozzle portion 65 is pressed (the black arrow in FIG. 5). The standing portion 81 also releases the energy absorbed by the elastic deformation and presses the inner surface of the nozzle portion 65 as indicated by the white arrow in FIG. Then, the duct portion 66 around the air jet port 64 is brought into close contact with the raised portion upper surface portion 722 around the cave 721 and sealed. In the present embodiment, the duct surface portion 66a existing on the inner peripheral side and the outer peripheral side of the annular recess 662 is in contact with the upper surface portion 722 of the raised portion so as to adhere and seal (FIG. 5).

  In such a set of ducts to the foaming mold 7, the duct 6 has a duct main portion formed on substantially the same plane arranged horizontally, and an upstanding nozzle portion 65 is accommodated in the cave 721, and the adhesion and seal are The mouth of the air spout 64 that fits in the cave 721 is closed. An air introducing portion 61 projects upward from the duct main portion.

  Concurrently with the setting of the duct 6 to the foaming mold 7, the present embodiment sets the nonwoven fabric 91 on the mold surface 76 of the upper mold 7b as shown in FIG. This is because when the seat pad 1 with the duct 6 is formed, the nonwoven fabric 91 covers the duct 6 so that the nonwoven fabric 91 is integrally attached to the back surface 1b of the seat pad (FIG. 3). Note that FIG. 7 omits the illustration of the nonwoven fabric 91.

  Next, a predetermined amount of a foaming raw material m such as a urethane foam stock solution for forming a seat pad is injected into the mold surface 71 forming the cavity 70 of the lower mold 7a with the mold open state of FIG. To do.

Subsequently, the upper mold 7b is operated to close the mold (FIG. 7). By closing the upper die 7b and the lower die 7a, the seat pad 1 cavity 70 in which the duct 6 is insert-set is formed.
In this embodiment, after setting the duct 6 to the foaming mold 7, the foaming raw material m is injected, and then the mold is closed. However, after setting the duct 6 to the foaming mold 7, the mold is closed, and then the foaming raw material m is added. It can also be injected.

After the mold closing, the main process is foam molding. The mold closed state of FIG. 7 is maintained for a predetermined time, and the seat pad 1 in which the duct 6 is embedded and integrated as shown in FIG. 3 is foam-molded.
Here, if the leaf spring body 8 is not provided, even if the duct 6 is set in the lower mold 7 a and the mold is closed, the duct 6 is warped or deformed, and a gap or duct 6 is formed between the lower mold 7 a and the duct 6. There is also a risk of floating. There may be a case where the air jet port 64 cannot be blocked. However, according to the present invention, the leaf spring body 8 is disposed in the cave 721, and as described above, the upright portion 81 and the guide portion 83 are raised by the energy due to elastic recovery, and the duct surface portion 66a around the air jet port 64 is raised. The top surface portion 722 is forcibly pressed and sealed to close the mouth of the air jet port 64.

In the present embodiment, an annular recess 662 surrounding the air jet port 64 is further provided in the duct surface portion 66a. When the duct is set to the lower mold 7a, the upper surface portion 722 of the raised portion closes the annular recess 662 and abuts against the duct surface portion 66a. Duct surface portions 66 a located on the inner peripheral side and the outer peripheral side straddling the annular recess 662 abut on the upper surface portion 722 of the raised portion. Even if the pressure contact of the duct surface portion 66a to the upper surface portion 722 of the raised portion becomes weak for some reason, even if the foaming material m enters the air outlet 64 as shown in FIG. In this case, that becomes the buffer space pt. Foaming raw material m stays in the annular recess 662. Simultaneously with the retention, the foaming raw material m begins to harden, preventing further subsequent foaming raw material m from entering.
Here, there is no particular problem with the duct of the other form in which the annular recess 662 as shown in FIG. 8 instead of FIG. 5 is provided, but by providing the annular recess 662 as in this embodiment, the foaming raw material at the time of foam molding is provided. m can be completely prevented from entering the air outlet 64, which is more preferable. In addition, the code | symbol j of FIG. 8 shows the contact | abutting and contact | adherence part of the duct part 66 and the protruding part upper surface part 722. FIG.

  Under the set of the duct 6 and the nonwoven fabric 91 to the foaming mold 7, the seat pad 1 is foam-molded by inserting the duct 6 and the nonwoven fabric 91. The dent portion 21 is formed in the seat pad surface 1a on the occupant contact side at the raised portion 72, and the seat pad 1 with the duct 6 is formed by foaming so that the dent portion 21 is aligned with the air jet port 64 to form the air outlet port 20. The The nonwoven fabric 91 covers substantially the entire back side of the duct 6. The non-woven fabric 91 covering the duct back surface portion 66b has an effect of preventing the duct 6 from peeling off from the seat pad 1 due to deformation of the seat pad 1 when the product is used by sitting on the passenger. Reference numeral 5 denotes an elastic seal portion that wraps around the air introduction portion 61. The foam raw material m enters the recess 73 during foam molding, and the elastic seal portion 5 is simultaneously molded with the seat pad 1.

  When the foam molding of the seat pad 1 is finished and removed, the desired seat pad 1 with the duct 6 is obtained (FIGS. 1 to 3). When the seat pad 1 with the duct 6 is covered with the skin 99, it becomes a seat cushion for a seat of a vehicle seat.

(2) Embodiment 2
This embodiment is a manufacturing method of a seat pad with a duct having the leaf spring body 8 of FIGS. 9 and 10 and the foaming mold 7 used for the method. 9 is an explanatory cross-sectional view in which a duct is set in a foaming mold 7 having a leaf spring body 8 different from that of the first embodiment, a cross-sectional view corresponding to FIG. 5, and FIG. The explanatory sectional view concerning is shown.

As in the first embodiment, the foaming mold 7 has a cave 721 dug down from the upper surface portion 722 of the raised portion 72 that forms the recess 21, and two opposing plate pieces 8 b are elastic in the cave 721. A leaf spring body 8 is provided, which has an emissivity and maintains the mutually facing distance. However, unlike the first embodiment, the leaf spring body 8 is not fixed to the cave bottom surface 721b, and the bottom piece 8a is normally attracted to the cave bottom surface 721b by the elastic biasing force of the compression coil spring sg. The leaf spring body 8 is attached to the cave 721 so as to be movable up and down.
Specifically, a through hole th that penetrates from the cave bottom surface 721b to the lower mold lower surface 7a ₁ is formed in the lower mold 7a, and a movable shaft body K that inserts the shaft portion sh is provided in the through hole th (FIG. 9). . The movable shaft K is fixed and integrated around the head he of the shaft sh to the bottom piece 8a of the leaf spring body 8, while the shaft sh passing through the through hole th and the presser plate dc fixed to the tip of the shaft. Between them is a compression coil spring sg. The plate spring body 8 integrated with the movable shaft body K normally receives an urging force that is pressed against the cave bottom surface 721b by the compression coil spring sg (a in FIG. 10), while applying an external force against the compression coil spring sg. In addition, as shown in FIG. 10 (b), the structure can float from the cave bottom surface 721b.

In the first embodiment, the annular recess 662 is provided in the duct, but an annular groove 723 is provided in the foaming mold 7 instead. An annular groove 723 is formed in the upper surface portion 722 of the raised portion around the cave 721, and the duct surface portion 66 a related to the duct portion 66 around the air outlet 64 is set in the annular groove 723 in the set of the duct 6 to the foaming mold 7. Is in contact with the upper surface portion 722 of the raised portion.
The configuration of the other foaming mold 7 is the same as that of the first embodiment, and the description thereof is omitted. The same reference numerals as those in the first embodiment denote the same or corresponding parts.

  The manufacturing method of the seat pad with a duct using the foaming mold 7 is slightly different from the first embodiment in the setting of the duct to the foaming mold 7.

  Each nozzle part 65 is accommodated in the cave 721 by setting the duct to the foaming mold 7, but the nozzle part 65 can be held by the guide part 83 as in the first embodiment only by placing the duct in the lower mold 7a. . The duct is in a state where it floats from the raised portion 72 while the tip portion of the nozzle portion 65 covers the guide portion 83 and accommodates a part thereof (FIG. 10A). Therefore, the duct is placed on the lower mold 7 a so that the air jet port 64 of the nozzle portion 65 faces the guide portion 83 in the cave 721, and a part of the guide portion 83 is taken into the nozzle portion 65. Next, the back side duct portion 66 of the nozzle portion 65 is pressed toward the raised portion 72 with a hand or the like. Further, in this embodiment, in synchronization with this, the presser plate dc is pushed up by an air cylinder rod or the like (not shown) against the urging force of the compression coil spring sg, and the movable shaft body K and the leaf spring body 8 are moved upward ( (B) The white arrow in FIG.

By the pressing of the nozzle portion back side duct portion 66 toward the leaf spring body 8 and the upward movement of the movable shaft body K and the leaf spring body 8, the guide portion 83 and the standing portion 81 are elastically deformed in a direction approaching each other and energy Absorb (black arrow in FIG. 10). The nozzle portion 65 slides down the surfaces of the guide portions 83 whose widths are narrowed due to elastic deformation, climbs over the guide portion 83 and the overhang portion 82 in an instant, and fits in the cave 721 (FIG. 9). At the same time, the pressing of the nozzle portion rear side duct portion 66 toward the leaf spring body 8 and the upward movement of the movable shaft body K and the leaf spring body 8 are released.
When the guide portion 83 and the overhang portion 82 pass through the nozzle portion 65 and enter the duct, the guide portion 83 and the overhang portion 82 are released from the restriction of the nozzle portion 65 and release the energy absorbed by the elastic deformation. The air jet outlet peripheral inner surface 66d, in other words, the duct inner surface 66d around the base end of the nozzle portion 65 is pressed (FIG. 9). Then, the duct portion 66 around the air jet port 64 is brought into close contact with the raised portion upper surface portion 722 around the cave 721 and sealed. The standing portion 81 also releases the energy absorbed by the elastic deformation, and presses the inner surface of the nozzle portion 65 to closely adhere and seal it.

Further, in the present embodiment, the compression coil spring sg is elastically restored, and the leaf spring body 8 floating from the cave bottom surface 721b is pulled toward the cave bottom surface 721b by the urging force of the compression coil spring sg. As a result, the projecting portion 82 of the leaf spring body 8 strongly pulls the duct inner surface 66d around the base end of the nozzle portion 65 into the cave 721, and the duct portion 66 around the air ejection port 64 is moved around the cave 721. It is made to adhere more strongly to the raised portion upper surface portion 722. Both of the sealing properties are further enhanced, and the opening of the air jet port 64 is more reliably closed with a set of ducts to the lower mold 7a.
In addition, the present embodiment is a set of the duct 6 to the lower mold 7a, and the duct surface portion 66a related to the duct portion 66 around the air outlet 64 is formed on the raised portion upper surface portion 722 so as to block the annular groove 723. Abutting and adhering to each other to ensure complete sealing (Fig. 9).

  The rest is the same as in the first embodiment, and the details are omitted. However, the nonwoven fabric 91 is set in the upper mold 7b in parallel with the setting of the duct 6, and the foaming raw material m is injected into the lower mold 7a in the mold open state. Thereafter, the mold is closed, and the seat pad 1 in which the duct 6 is embedded and integrated is foamed to obtain the desired seat pad 1 with the duct 6. The same reference numerals as those in the first embodiment denote the same or corresponding parts.

(3) Effect According to the manufacturing method of the seat pad with the duct configured as described above and the foaming mold 7 used therefor, the two plate pieces related to the leaf spring body 8 with the duct 6 set to the foaming mold 7 8b enters the duct 6 from the air jet port 64 so as to close the space between each other, and further, the distance where the two plate pieces 8b are packed is expanded by elastic restoration, so that the duct inner surface 66d can be moved from the inside of the duct. Since the duct portion 66 around the air jet port 64 is forcibly pressed and tightly sealed with the raised portion upper surface portion 722 around the cave 721, the mouth of the air jet port 64 can be closed. Unlike simply setting the duct on the mold surface, the duct portion 66 around the air outlet 64 is pressed against the upper surface portion 722 of the raised portion around the cave 721 by the elastic restoring force of the leaf spring body 8, so that the sealing property Will increase. Subsequent foam molding can prevent the foam material m from entering the duct 6 from the air jet port 64.

The leaf spring body 8 disposed in the cave 721 has two upright portions 81 extending from the bottom piece 8a to the upper side of the cave opening 721a in a reverse C shape in front view, and both projecting portions at the tip. 82 bends outward and extends approximately horizontally outward so that they are spaced from each other. Further, the guide part 83 is refracted toward the bottom piece 8a side at the tip of the projecting part 82, and the distance between the two guide parts 83 is reduced in a taper shape, so that the duct 6 is set on the lower mold 7a. It becomes easy.
By simply pressing the back side duct portion 66 of the nozzle portion 65 that can be used by the guide portion 83 on the cave 721 by setting the duct to the lower mold 7a, the tip of the nozzle portion 65 forming the air jet port 64 is both The guide part 83 is pressed and elastically deformed to bring them closer together, and the both standing parts 81 are also elastically deformed to bring them closer together (dashed line in FIG. 5). The nozzle portion 65 causes the guide portion 83 to enter the nozzle portion 65 and moves toward the cave 721 while sliding down the surface of the guide portion 83. Then, the nozzle part 65 gets over the guide part 83 and the overhang part 82, and the setting of the duct 6 to the lower mold 7a is completed without difficulty.

On the other hand, the pressure that presses the back side duct portion 66 of the nozzle portion 65 from above is temporarily absorbed by the elastic deformation of the guide portion 83 and the overhang portion 82. The energy is released when the nozzle portion 65 gets over the guide portion 83 and the overhang portion 82, and the overhang portion 82 and the standing portion 81 strongly press the duct inner surface 66d around the air outlet 64 from the inside of the duct. . With this pressing force, the duct portion 66 around the air jet port 64 is pressed against the upper surface portion 722 of the raised portion around the cave 721 to closely adhere and seal (solid line in FIG. 5).
By simply pressing and setting the duct on the lower die 7a from above as described above, the sealing performance of the duct portion 66 and the raised portion 72 around the air outlet 64 is improved, and no special new device or the like is required. Utilizing the force to press down the duct, the self-acting action of the leaf spring body 8 that makes good use of energy absorption by elastic deformation and energy release by elastic restoration improves the tight seal performance between the duct surface portion 66a and the raised portion 72. Can do.

Up to now, even if the air jet port 64 of the duct 6 is closed against the mold surface, the foam 6 is inserted into the foaming die 7 and the seat pad 1 is foam-molded, the foaming material m is ducted from the air jet port 64. There was a problem of entering into 6. In particular, in the seat pad 1 including the duct 6 of the vehicle seat, a plurality of air jets 64 are distributed and arranged at the end of the duct 6 as shown in FIG. 1, and each air jet 64 is closed and foamed. Even though I was going to set it on the mold 7, it was easy to have a problem that somewhere was floating. It was difficult to integrally foam the seat pad 1 in which the duct 6 was embedded while avoiding the intrusion of the foaming raw material m into the duct from the air jet port 64.
With respect to such a problem, the present invention is a set of ducts to the foaming mold 7, and the duct surface portion 66 a surrounding the air jet port 64 with the force of the leaf spring body 8 disposed in the cave 721 is formed into the recess 21. The air outlet 64 is covered with the raised portion 72 that forms the shape. With the elastic restoring force of the leaf spring body 8, the dimensional error of the air jets 64 (specifically, the duct surface portion 66a surrounding the air jets 64) distributed at each end of the duct 6 is eliminated. . Even if a slight dimensional error occurs in the contact state between the duct surface portion 66a and the raised portion 72, the elastic force of the leaf spring body 8 forcibly pressing it from the inside of the duct causes the duct surface portion 66a to be raised. 72 is closely attached and sealed. Absorbs dimensional errors in each part. In the foam molding of the seat pad 1 in the next step, the foam raw material m can be well prevented from entering the duct 6 from the air jet port 64.

  Further, as in the second embodiment, if the leaf spring body 8 is brought into close contact with the cave bottom surface 721b by the elastic biasing force of the compression coil spring sg, the elastic restoring force of the compression coil spring sg is also applied, so that the leaf spring body 8 The duct surface portion 66a surrounding the outlet 64 is drawn into the cave 721, which is more preferable. It is a meteorite that absorbs the dimensional error of each part more effectively, and adheres and seals the duct surface portion 66a to the raised portion 72.

In addition, an annular recess 662 surrounding the air ejection port 64 is provided in the duct surface portion 66a surrounding the air ejection port 64, and in the set of the duct to the foaming mold 7, the ridge upper surface portion 722 has the annular recess 662. If the duct surface portion 66a comes into contact with the duct surface portion 66a so as to be closed, even if a gap is formed between the raised portion upper surface portion 722 and the duct surface portion 66a for some reason, the foam raw material m to the air outlet 64 is formed during foam molding. It can easily cope with the intrusion prevention. Even if the foam raw material m enters the air outlet 64 during foam molding (arrow in FIG. 6), it once enters the annular recess 662, where the foam raw material m is cured and the subsequent intrusion is cut off. The annular recess 662 becomes the buffer space pt, and the foaming raw material m that has entered enters here. As the foaming raw material m stagnates, curing also starts with time and prevents further subsequent foaming raw material m from entering. There is no problem even if a foaming pressure rises at the time of foam molding, and a gap is formed between the raised portion upper surface portion 722 and the duct surface portion 66a.
Even if the annular groove 723 is formed in the upper surface portion 722 of the raised portion 72 of the foaming mold 7 in place of the annular recess 662, the same effect as the annular recess 662 is obtained.

If the foam raw material m enters the duct 6 from the air jet 64, the air jet 64 has a considerable distance from the seat pad surface 1a in order to obtain the cushioning property of the seat pad 1. It is extremely difficult to remove the foam material m. The seat pad 1 with the duct 6 formed by simply bringing the conventional air jet port 64 into contact with the mold surface is forced to reduce the yield. If the foamed raw material m in the duct 6 is left as it is, the ventilation resistance of the duct 6 is increased, and the seat for adjusting the temperature for comfort is hindered.
On the other hand, the manufacturing method of the seat pad with the duct 6 and the foaming mold 7 used therefor are the foaming raw material m at the time of foaming the seat pad by the leaf spring body 8, the annular recess 662 and the annular groove 723 as described above. Can be completely prevented from entering the air jet port 64, eliminating the operation of removing the foaming material m that has entered the duct 6, and improving the yield. Since the leaf spring body 8, the annular recess 662, and the annular groove 723 improve the sealing performance of the air outlet 64 during foam molding, the dimensional accuracy of the duct 6 can be allowed to some extent. It also leads to cost reduction of products.

  The present invention is not limited to those shown in the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, and the like of the seat pad 1, the duct 6, the duct portion 66, the foaming die 7, the raised portion 72, the leaf spring body 8, and the like can be appropriately selected according to the application. For example, in the embodiment, the nozzle portion 65 for the air jet port 64 is provided, but without providing the nozzle portion 65, a hole can be directly formed in the duct 6 to be used as the air jet port 64. The annular recess 662 and the annular groove 723 may be used in combination.

1 Seatpad 1a Surface (Seatpad surface)
1b Back side (Seat pad back side)
20 Air outlet 21 Dimple 6 Duct for air distribution (duct)
61 Air introduction part 64 Air jet outlet 66 Duct part (duct part around the air jet outlet)
66a Duct surface portion 662 Annular recess 7 Foam type 72 Raised portion 721 Cave 722 Raised portion upper surface portion 723 Annular groove 8 Leaf spring body 8b Plate piece m Foaming raw material

Claims (4)

The air distribution duct (6) provided with the air introduction part (61) and the air outlet (64) in the duct path is set in the foaming mold (7), and then the foaming raw material (m) is injected. And through the mold closing, the seat pad (1) in which the duct (6) is embedded is foam-molded, and the depression (21) formed on the seat pad surface (1a) on the passenger contact side by the foam molding is described above. A method for manufacturing a seat pad with a duct to be an air outlet (20) according to an air outlet (64),
A cave (721) is dug down from the upper surface portion (722) of the raised portion (72) forming the depression (21), and two plate pieces (8b) facing each other in the cave (721). Using a foaming mold (7) provided with a leaf spring body (8) having elasticity and maintaining a mutual facing distance,
In the set of the duct (6) to the foaming mold (7), the two plate pieces (8b) are packed into the duct (6) from the air outlet (64) so that the distance between them is reduced. Further, the distance between the two plate pieces (8b) is expanded by elastic restoration, and the duct portion (66) around the air outlet (64) is moved around the cave (721). The seat pad (1) is integrally foamed by inserting the duct (6) through intimate contact with the upper surface portion (722) of the raised portion and then injecting the foam raw material (m) and closing the mold. A manufacturing method of a seat pad with a duct. An annular recess (662) surrounding the air jet port (64) is further provided on the duct surface portion (66a) of the duct portion (66) around the air jet port (64), to the foaming mold (7). The manufacture of a seat pad with duct according to claim 1, wherein the upper surface portion (722) of the raised portion abuts against the surface portion (66a) of the duct so as to block the annular recess (662). Method. An annular groove (723) is further formed in the upper surface portion (722) of the raised portion around the cave (721), and a set of ducts (6) to the foaming mold (7), and around the air outlet (64) 3. A ducted seat pad according to claim 1 or 2, wherein a duct surface portion (66a) related to the duct portion (66) abuts on the upper surface portion (722) of the raised portion so as to block the annular groove (723). Manufacturing method. The air distribution duct (6) provided with the air introduction part (61) and the air outlet (64) in the duct path is set in the foaming mold (7), and then the foaming raw material (m) is injected. And through the mold closing, the seat pad (1) in which the duct (6) is embedded is foam-molded, and the depression (21) formed on the seat pad surface (1a) on the passenger contact side by the foam molding is described above. The foaming mold used in the method for manufacturing a seat pad with a duct to be an air outlet (20) according to the air outlet (64),
A cave (721) is dug down from the upper surface portion (722) of the raised portion (72) forming the depression (21), and two plate pieces (8b) facing each other in the cave (721). Is provided with a leaf spring body (8) that has elasticity and maintains the opposing distance between each other,
In the set of the duct (6), the two plate pieces (8b) enter the duct (6) from the air outlet (64) so as to close the space between each other. By expanding the distance packed with the plate piece (8b) by elastic restoration, the duct portion (66) around the air outlet (64) is connected to the upper surface portion (722) of the raised portion around the opening of the cave (721). The foaming mold used for the manufacturing method of the sheet pad with a duct characterized by making it closely_contact | adhere to.

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