JP2012081161A - Seat pad containing duct and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a seat pad containing a duct for preventing a foaming raw material from entering the duct from an air outlet when embedding the duct for air distribution including the air outlet provided in a duct path to integrally foam-mold the seat pad.SOLUTION: The seat pad containing a duct includes: the duct 6 for air distribution including an air inlet 61, and the air outlet 64 provided in the duct path; a cushioning member 8 having a cushioning property; and the seat pad 1 integrally foam-molded by forming a recess 21 on a surface 1a at an occupant abutting side, by setting the recess 21 to be an air blowout port 20 communicating with the air outlet 64, and by inserting the duct 6 for air distribution and the cushioning member 8. The cushioning member 8 is embedded at a side of a rear 1b of the seat pad 1, and also the cushioning member 8 abuts on a duct back portion 66b, namely a side opposite to the air outlet 64, at a duct section 66 of which the air outlet 64 is formed.

Description

  The present invention relates to a seat pad for a seat cushion that constitutes a vehicle seat, and relates to a duct-containing seat pad in which a duct is integrated by insert molding, and a method for manufacturing the same.

  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 material leaks into the duct by simply closing the vent against the mold surface. Furthermore, since the foaming pressure at the time of foam molding is increased, if the vent hole is not sufficiently blocked, the foaming 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 and a method of manufacturing the same that can prevent the above-described problem, improve the yield, and eliminate the operation of removing the foaming raw material that has entered the pipe.

To achieve the above object, the gist of the invention described in claim 1 is that a duct for air distribution (6) provided with an air introduction part (61) and an air outlet (64) in the duct path, and a cushion. A cushioning member (8) having a characteristic, and a dent (21) is formed in the surface (1a) on the occupant contact side, and the dent (21) communicates with the air outlet (64). The air distribution duct (6), and further comprising a seat pad (1) integrally foamed by inserting the buffer member (8), the buffer member (8) Embedded in the back surface (1b) side of the seat pad (1) and the buffer member (8) is a duct part (66) in which the air outlet (64) is formed, and the air outlet (64) A seat pad with a duct, which is in contact with a duct back surface portion (66b) on the opposite side.
The ducted seat pad according to a second aspect of the present invention is the seat pad with a duct according to the first aspect, wherein the shock-absorbing member (8) has a plate shape having an impregnation property, and one plate surface abuts against the duct back surface portion (66b). The other plate surface on the opposite side forms the same surface as the back surface (1b) of the seat pad (1). A ducted seat pad according to a third aspect of the present invention is the seat pad with a duct according to the first or second aspect, further comprising a non-woven fabric (91), and the non-woven fabric (91) includes the cushioning member (8) and the duct back surface portion (66b). Covering the included duct (6), the seat pad (1) is foam-molded and attached to the back surface (1b) of the seat pad (1). A ducted seat pad according to a fourth aspect of the present invention is characterized in that, in the first to third aspects, the buffer member (8) is a press felt. A ducted seat pad according to a fifth aspect of the present invention is the duct portion (66) in which the air spout (64) is formed in the first to fourth aspects, and the air spout (66a) is formed on the duct surface portion (66a). An annular recess (662) surrounding 64) is further formed.
The gist of the invention described in claim 6 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 method of manufacturing a duct-filled seat pad in which a recess (21) formed in the air outlet (64) is formed in accordance with the air outlet (64) for air distribution to the foaming mold (7). Along with the set of the duct (6), a cushioning member (8) having a cushioning property is set in the foaming mold (7), and then the air outlet (64) is formed by closing the mold. In the compressed duct portion (66), the buffer member (8) is brought into contact with the duct back surface portion (66b) on the opposite side of the air outlet (64) in a compressed state, and the depression (21) The air jet port (64) is closed by the raised portion (72) of the foaming mold (7) to be formed, and then the cushioning member (8) is foamed by the seat pad (1) so that the cushioning member (8) is the seat pad ( 1. A method of manufacturing a ducted seat pad characterized by being embedded and integrated on the back surface (1b) side of 1).
According to a seventh aspect of the present invention, there is provided a duct seat pad manufacturing method according to the sixth aspect, wherein the duct surface portion (66a) surrounding the air outlet (64) is provided with an annular recess (662) surrounding the air outlet (64). ), And the upper end surface (722) of the raised portion (72) abuts on the duct surface portion (66a) so as to close the annular recess (662) by closing the mold. According to an eighth aspect of the present invention, there is provided a method for manufacturing a seat pad with a duct according to the sixth aspect of the present invention. In addition, an annular groove (723) is further formed, and by closing the mold, the duct surface portion (66a) is in contact with the upper end surface (722) of the raised portion (72) so as to block the annular groove (723). It is characterized by.

As in the first and sixth aspects of the invention, the cushioning member (8) having a cushioning property is a duct portion (66) in which the air ejection port (64) is formed, and the duct corresponds to the opposite side of the air ejection port (64). If provided so as to contact the back surface portion (66b), the cushioning property of the buffer member can be utilized to more reliably close the mouth of the air jet port (64). When foaming the seat pad, it is possible to prevent the foam material from entering the duct from the air jet.
As in the second aspect of the present invention, one plate surface of the buffer member (8) contacts the duct back surface portion (66b), while the other plate surface on the opposite side is flush with the back surface (1b) of the seat pad (1). If such a surface is formed, the cushioning member sandwiched between the foam mold and the duct can be easily compressed when the seat pad is foam-molded. It can be done relatively easily. When the cushioning member (8) has impregnation properties, the foaming material is appropriately absorbed and impregnated by foam molding of the seat pad, so that the cushioning member and the seat pad can be integrally strengthened. In addition, on the back side of the seat pad, the plate-like cushioning member that covers the duct can soften the collision and impact applied to the duct and protect it.
As in the invention of claim 3, further comprising a non-woven fabric (91), the non-woven fabric (91) covering the duct (6) including the buffer member (8) and the duct back surface portion (66b), When the seat pad (1) is foam-molded and adhered to the back surface (1b) of the seat pad (1), the nonwoven fabric covers and integrates even if the buffer member does not have impregnation properties. Therefore, there is an effect that the buffer member and the duct are not peeled off from the seat pad. If the cushioning member (8) is a press felt as in the invention of claim 4, it has not only cushioning and impregnation properties, but also appropriate flexibility, followability and stiffness required for the backing member for this duct. And is extremely effective in the production of a seat pad with a duct. When the annular recess (662) surrounding the air outlet (64) is further formed in the duct surface portion (66a) as in the inventions of claims 5 and 7, the annular recess is formed during foam molding of the seat pad. Therefore, it is possible to prevent the foaming raw material from entering the duct from the air outlet.
As in the invention of claim 6, by closing the mold, the cushioning member (8) is brought into contact with the duct back surface portion (66b) on the opposite side of the air jet port (64) in a compressed state, and the raised portion (72) When the air ejection port (64) is closed, the cushioning member in a compressed state presses the duct portion against the bulging portion by its elastic restoring force, so the bulging portion (72) makes the air ejection port (64) more effective. Can be blocked. As in the invention of claim 8, an annular groove (723) is further formed on the upper end surface (722) of the raised portion (72) contacting the duct surface portion (66a) surrounding the air jet port (64), and the mold is closed. Thus, when the duct surface portion (66a) closes the annular groove (723) and comes into contact with the upper end surface (722) of the raised portion (72), the annular groove becomes a buffer space during foam molding of the seat pad. Therefore, it is possible to successfully prevent the foaming raw material from entering the duct from the air outlet.

  The seat pad with duct of the present invention and the manufacturing method thereof can prevent the foaming raw material from entering the duct from the air jet port during foam molding of the seat pad, improve the yield, improve the work efficiency and productivity, Excellent effects such as contributing to quality improvement.

FIG. 3 is an overall perspective view of the seat pad with duct according to the present invention, as viewed from the front surface side of the seat pad indicated by a chain line. It is the whole perspective view seen from the surface side of the seat pad with a duct seen from the angle different from FIG. It is the III-III arrow directional view of FIG. FIG. 5 is an explanatory cross-sectional view in which a duct for air distribution and a buffer member are set in a foaming mold and a foaming raw material is injected by the method for manufacturing a seat pad with a duct according to the present invention. It is the elements on larger scale of FIG. FIG. 6 is an enlarged view of another embodiment instead of FIG. 5. FIG. 5 is an explanatory sectional view proceeding from FIG. 4 to a mold closing step.

  Hereinafter, the seat pad with duct according to the present invention and the manufacturing method thereof will be described in detail. 1 to 7 show one embodiment of a seat pad with a duct and a method for manufacturing the same according to the present invention. FIG. 1 is an overall perspective view of the seat pad represented by a two-dot chain line from the surface side, and FIG. FIG. 3 is a perspective view taken along the line III-III in FIG. 2, and FIG. 4 is a view of setting a duct for air distribution and a cushioning member in a foaming mold, and injecting a foaming raw material. FIG. 5 is a partially enlarged view of FIG. 4, FIG. 6 is a diagram showing another embodiment instead of FIG. 5, and FIG. 7 is an explanatory sectional view proceeding from FIG. 4 to the mold closing process. In addition, although the tongue piece-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.

(1) Manufacturing Method of Ducted Seat Pad The manufacturing method of the ducted seat pad uses the foaming mold 7 and the air distribution duct 6 (hereinafter simply referred to as “duct”) and the buffer member 8. Then, after the foaming raw material m is injected and the mold is closed, the seat pad 1 as shown in FIGS. 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, a buffer member 8, and a foaming 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 a plan view as shown in FIGS. 1 and 2, 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 surrounding the air jet port 64 is not circular in cross section, but has a flattened oval shape as shown in FIGS. The duct surface portion 66a related to the duct portion 66 and the duct back surface portion 66b facing the duct surface portion 66a via the flow path 60 form a flat surface, and both are joined by an arc-shaped duct side surface portion 66c. To do. As shown in FIGS. 1 and 5, the duct surface portion 66 a is further formed with an annular recess 662 that is recessed in the shape of a narrow ring groove 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 back surface portion 66b related to the duct portion 66 surrounding the air jet port 64 is formed on a flat surface, but also the entire back surface side of the duct vertical tube portion 6a and the horizontal tube portion 6b is shown in FIG. The buffer member 8 formed on the flat surface as described above and disposed on the back surface side of the duct 6 makes it easy to contact the entire flat surface.

On the other hand, an air introduction portion 61 is provided on the back side of the duct 6. The foam duct of the seat pad 1 is an insert duct 6 in which the main part of the duct is embedded, but the cylindrical air introduction portion 61 protrudes from the seat pad back surface 1b. At the stage where the seat pad 1 with the duct 6 is completed, the air introduction portion 61 whose front end opening becomes the air introduction opening e protrudes from the center of the back surface 1b of the seat pad (FIG. 3). Specifically, the bulging portion 6b ₁ projects at the approximate center of the horizontal tube portion 6b (FIG. 1). Swollen portion 6b ₁ is bent to the back side at the tip, a cylindrical air inlet section 61 which is extended to form an air inlet e. The air introduction part 61 stands up with respect to the main part of the duct 6 on substantially the same plane.

The buffer member 8 is a duct portion 66 in which an air jet port 64 is formed. As shown in FIG. 3, the buffer member 8 is a plate (sheet-like) disposed on a duct back surface portion 66 b on the opposite side of the air jet port 64. Including). The buffer member 8 is impregnated and cushioned, and is set in the foaming mold 7 together with the duct 6. A buffer member 8 is interposed between the duct 6 and the upper mold 7b, and the buffer member 8 is compressed by closing the mold. Although the buffer member 8 is initially plate-like body having a cushioning property in the thickness t ₁ (FIG. 4), and compressed sandwiched by the upper mold 7b and the duct 6 in the mold closing, the thickness t ₂ (Figure 7) . As a result, the buffer member 8 presses the duct 6, and the air ejection port 64 is closed so as to seal the mouth with the raised portion 72 of the foaming mold 7 that molds the recess 21. In this embodiment, the tight sealing force between the duct surface portion 66a and the raised portion 72 of the foaming mold 7 that forms the recess 21 is increased, and the sealing performance that covers the mouth of the air jet port 64 is ensured.
The shock-absorbing member 8 of the present embodiment is a seat pad main portion that covers not only the duct back surface portion 66b on the opposite side of each air outlet 64 but also the back surface side of the duct 6 related to the vertical tube portion 6a and the horizontal tube portion 6b. While being spread over almost the entire area of 2, the size in plan view is slightly smaller than the main part (FIG. 3). The cushioning member 8 has a substantially rectangular shape in plan view and covers four locations of the air outlet 64 where the annular recess 662 is present at the four corners of the vertical cylindrical portion 6a. A hole 81 through which the air introduction part 61 passes is provided in the center of the buffer member 8.

  The buffer member 8 has a cushioning property that contributes to a tight seal between the duct surface portion 66a and the raised portion 72 by being compressed by closing the mold as described above. And it is formed with the material which the foaming raw material m permeates by foam molding. The cushioning member 8 has impregnating properties and cushioning properties as structural characteristics, and a nonwoven fabric or press felt is suitable, but press felt is more preferable. Press felt is originally a fiber product made by shrinking wool such as wool, and using a special scale-like surface shape of wool and other fibers, the fibers are entangled with each other by moisture, heat, and pressure. Finished. The press felt is a compression based on its cushioning property, exerts its power in tight seal between the duct surface portion 66a and the raised portion 72, and has an impregnation property that absorbs the foaming raw material m appropriately with the seat pad 1 ( This is useful for preventing noise in the duct 6 (described later). Furthermore, due to the manufacturing method of making a strong sheet-like body by applying humidity and pressure to the fluffy laminate made of wool, etc., there is a certain degree of flexibility, followability and stiffness required as a backing member for the duct 6 Yes, it is a perfect fit for the buffer member 8. The buffer member 8 of this embodiment is also made of press felt.

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 with the hinge as a fulcrum, the mold surface 71 of the lower mold 7a is recessed in the shape of a bowl, and the mold surface 76 of the generally flat upper mold 7b having a recess 73 in part. Thus, the cavity 70 of the seat pad 1 with the duct 6 is formed. 1 to 7, the sheet pad surface 1a side is formed by the mold surface 71 of the lower mold 7a, and the sheet pad back surface 1b side is molded by the mold surface 76 of the upper mold 7b (FIGS. 3 and 4). ). Part of the seat pad back surface 1b is occupied by the buffer member back surface 8b. The main part mold surface 76a of the upper mold 7b for forming both back surfaces is made to be substantially flat so that the plate surface on the buffer member back surface 8b side forms a uniform surface with the seat pad back surface 1b. To do.
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. In each raised portion 72, the lower portion 72 b is responsible for forming the recess 21, and the upper portion 72 a is further responsible for sealing the air outlet 64. A mortar-shaped hole 721 is dug in the center of the upper end surface 722 of each raised portion 72, and an annular upper end surface 722 in which a flat surface remains in a strip shape on the outer periphery of the hole 721 (FIG. 5). When the mold is closed, the nozzle portion 65 is accommodated in the hole 721, and the duct surface portion 66a surrounding the air jet port 64 is in contact with the upper end surface 722 of the raised portion so as to cover and close the mouth of the air jet port 64. (FIGS. 5 and 7). When the seat pad 1 is formed by foam molding after mold closing, the raised portion 72 forms a recess 21 in the seat pad surface 1a on the passenger contact side, and the recess 21 communicates with the air jet port 64. It becomes the air outlet 20. 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, the duct 6 and the buffer member 8, 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 is set in the lower mold 7a in the mold open state. Each nozzle part 65 is accommodated in the hole 721 facing downward, and the duct 6 is set in the lower mold 7 a so that the duct surface part 66 a surrounding the air outlet 64 abuts against the upper end surface 722 of the raised part. In the duct 6, a duct main portion formed on substantially the same plane is horizontally arranged, and the standing nozzle portion 65 is accommodated in the hole 721, while the air introduction portion 61 projects upward from the duct main portion. 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 further in contact with the upper end surface 722 of the raised portion (FIG. 5).

  The cushioning member 8 is set in the foaming mold 7 in parallel with the setting of the duct 6. The buffer member 8 is disposed so as to be placed on the duct back surface portion 66 b on the opposite side of the air jet port 64 in the duct portion 66 around the air jet port 64. Here, after the duct 6 is set, the buffer member 8 is placed on the duct back surface portion 66b. The duct 6 is disposed along the back surface of the seat pad 1 via the buffer member 8. This is to secure the cushioning property of the seat pad 1 by setting the distance from the seat pad surface 1a to the air jet port 64, the duct vertical cylinder portion 6a, and the horizontal cylinder portion 6b as large as possible.

  In the present embodiment, the nonwoven fabric 91 is set 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 and the buffer member 8, and the nonwoven fabric 91 is integrally attached to the seat pad back surface 1b (FIG. 3). The nonwoven fabric 91 covers the duct 6 including the buffer member 8 and the duct back surface portion 66b, and is integrally attached to the seat pad back surface 1b by foam molding of the seat pad 1. 5 to 7 omit the illustration of the nonwoven fabric 91. The buffer member 8 may be set on the mold surface of the upper mold 7b. When the nonwoven fabric 91 is set on the upper mold 7b, the cushion member 8 may be overlapped with the nonwoven fabric 91 and set on the upper mold 7b after the nonwoven fabric 91 is set on the upper mold 7b.

  Next, with the mold open state of FIG. 4, the urethane foam stock solution for molding the seat pad, etc. using the injection hose h or the like on the mold surface 71 of the bowl-shaped dent forming the cavity 70 (FIG. 7) of the lower mold 7 a. A predetermined amount of the foaming raw material m is injected.

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 cavity 70 for the seat pad 1 in which the duct 6 and the buffer member 8 are insert-set is formed. As the mold is closed, the buffer member 8 comes into contact with the duct back surface portion 66b on the opposite side of the air jet port 64 in a compressed state.
Specifically, the duct 6 is set on the lower mold 7a, and the buffer member 8 is disposed and set on the duct back surface portion 66b as shown in FIG. In the seat pad cavity 70 after mold closing, while the interval between the upper mold molding surface 76 and the duct rear portion 66b as in FIG. 7 is t _2, the thickness t of the buffer member 8 disposed in FIG. 5 ₁ is set larger than the distance t _2. Therefore, after the buffer member 8 is disposed and set on the duct back surface portion 66b on the opposite side of the air jet port 64, when the mold is closed, the upper die 7b is connected to the duct as indicated by the white arrow in FIG. Press toward the back portion 66b. If the duct 6 is simply set on the lower mold 7a, the surroundings of the air outlet 64 of the duct 6 are lifted as indicated by the arrows in the enlarged view of the circle in FIG. There is a risk of entering into 6. In order to prevent this, the buffer member 8 is compressed by the duct 6 and the foaming mold 7 while the mold is closed. The buffer member 8 presses the duct back surface portion 66b by the elastic restoring force of the compression. Further, this pressing leads to a pressure contact between the duct surface portion 66a surrounding the air jet port 64 and the raised portion upper end surface 722, and the foam raw material m at the time of foam molding is prevented from entering the air jet port 64. The force that presses the duct portion 66 around the air outlet 64 to the raised portion 72 due to the compression of the buffer member 8 is configured to overcome the increase in foaming pressure during foam molding.
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 is used. m 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 and the buffer member 8 are embedded and integrated as shown in FIG. 3 is foam-molded.
Here, even if the duct 6 is set in the lower mold 7a and the mold is closed, the duct 6 is warped or deformed, and the gap or the duct 6 is lifted between the lower mold 7a and the duct 6 as described above. There is a case. There may be a case where the air outlet 64 cannot be sealed. However, according to the present invention, the buffer member 8 is configured to be compressed, and the duct surface portion 66a surrounding the air jet port 64 is urged to come into pressure contact with the upper end surface 722 of the raised portion, so that the mouth of the air jet port 64 is securely sealed. The shock absorbing member 8 in a compressed state is brought into contact with the duct back surface portion 66 b on the opposite side of the air outlet 64, and the air outlet 64 is effectively blocked by the raised portion 72.

  In the present embodiment, the annular recess 662 surrounding the air jet port 64 is further provided in the duct surface portion 66 a surrounding the air inlet port 64. By closing the mold, the upper end surface 722 of the raised portion closes the annular recess 662 and comes into contact with the duct surface portion 66a. When the mold is closed, the duct surface portion 66a on the inner peripheral side and the outer peripheral side of the annular recess 662 abuts against the upper end surface 722 of the raised portion. Even if the pressure contact of the duct surface portion 66a to the upper end surface 722 of the raised portion becomes weak for some reason, even if the foaming raw material m enters the air outlet 64 as indicated by the arrow shown in the enlarged view of the circle in FIG. When it enters the annular recess 662, it becomes a buffer, and the 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. In addition, by providing the nozzle portion 65 at the tip, the inner wall of the raised portion 72 that forms the hole 721 and the outer wall of the nozzle portion 65 are narrowed. It is difficult for the foaming raw material m to pass through the gap ε, and the foaming raw material m is almost completely prevented from reaching the air jet port 64.

  Under the set of the duct 6 and the buffer member 8 to the foaming mold 7, the duct 6 and the buffer member 8 are inserted and the seat pad 1 is foam-molded. 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 buffer member 8 in a compressed state covers substantially the entire back surface side of the duct 6, and the buffer member back surface 8b is substantially flush with the seat pad back surface 1b. The buffer member back surface 8b forms a surface that is uniform with the seat pad back surface 1b. The cushioning member 8 disposed so as to be placed on the duct back surface portion 66b is sandwiched between the duct 6 and the upper mold 7b, and the cushioning member 8 aligns the plate-like back surface 8b with the back surface 1b of the seat pad 1 so that the seat pad 1 is embedded and integrated. Further, the cushioning member 8 is impregnated with the foaming raw material m at the time of foam molding, and the integration with the seat pad 1 is strengthened. 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 a skin, it becomes a seat cushion for a seat of a vehicle seat.

  Incidentally, in this embodiment, the annular recess 662 is provided on the duct 6 side as shown in FIG. 5, but an annular groove 723 as shown in FIG. 6 can be provided on the foaming mold 7 side. The foaming mold 7 of FIG. 6 forms an annular groove 723 instead of the annular recess 662 on the upper end surface 722 of the raised portion that contacts the duct surface portion 66a surrounding the air jet port 64. By closing the mold, the duct surface portion 66 a is configured to abut against the upper end surface 722 of the raised portion 72 so as to block the annular groove 723. The annular groove 723 also exhibits the same action and effect as the annular recess 662.

(2) Seat pad with duct The seat pad 1 with duct 6 obtained by the above manufacturing method or the like is a seat pad 1 that is integrally foam-molded by inserting the duct 6 and the buffer member 8 (FIGS. 1 to 3). The duct 6 is provided with an air introduction portion 61 and an air outlet 64 is provided in the duct path. The buffer member 8 is a duct portion 66 in which the air ejection port 64 is formed, and is disposed on a duct back surface portion 66 b that is opposite to the air ejection port 64. The seat pad 1 has a recess 21 formed on the surface 1a on the passenger contact side, and the duct 6 and the buffer member 8 are inserted so that the recess 21 becomes an air outlet 20 communicating with the air outlet 64. Integrated foam molding. Further, in the foam molding of the seat pad 1, as shown in FIG. 3, the nonwoven fabric 91 covers the duct 6 and the buffer member 8, and is integrally attached to the seat pad back surface 1b.

And the said plate-shaped buffer member 8 is embed | buried under the seat pad back surface 1b side. One plate surface of the buffer member 8 contacts the duct back surface portion 66b, while the other plate surface on the opposite side forms a uniform surface with the back surface 1b of the seat pad 1. If the non-woven fabric 91 is not provided, the surface of the cushioning member 8 opposite to the surface contacting the duct back surface portion 66b is not covered with the foamed resin of the seat pad 1 and is exposed on the seat pad back surface 1b side. In foam molding of the seat pad 1, the cushioning member 8 is placed on the duct 6 set in the lower mold 7a, and the cushioning member 8 having cushioning properties is compressed by closing the foaming mold 7, and the duct back surface portion 66b is compressed. It is configured to press contact. This pressure contact maintains the close contact between the duct 6 and the lower mold 7a during foam molding of the seat pad 1. At the time of molding the seat pad 1, the contact and close contact between the duct surface portion 66 a surrounding the air jet port 64 and the raised portion 72 forming the depression 21 are ensured.
As a result, the duct surface portion 66a of the duct portion 66 surrounding the air jet port 64 is exposed to the seat pad 1 with the duct 6 without being covered by the seat pad 1 (FIGS. 2 and 3). The exposed portion indicates a trace portion in which the duct surface portion 66a abuts on and comes into close contact with the raised portion 72 that forms the recess 21 so as to cover the mouth of the air ejection port 64 during foam molding of the seat pad 1. The circular shape is slightly larger than the air jet port 64. When the mold is closed, the duct surface portion 66a on the inner peripheral side and the outer peripheral side straddles the annular recess 662 and abuts against the upper end surface 722 of the raised portion. Therefore, the annular recess 662 is also seen in a plan view of the seat pad 1. It is the seat pad 1 with the duct 6 that is exposed at (FIG. 2).
Other configurations such as the duct 6, the buffer member 8, the seat pad 1, and the nonwoven fabric 91 are the same as the configurations described in the method for manufacturing the seat pad 1 with the duct 6, and the description thereof is omitted.

(3) Effect According to the seat pad with a duct configured as described above and the method for manufacturing the same, the duct surface portion 66a surrounding the air outlet 64 is closed with the raised portion 72 forming the recess 21 by the mold closing. 64 is a duct portion 66 that covers the mouth of 64 and is formed with an air jet port 64. The buffer member 8 abuts against the duct back surface portion 66b on the opposite side of the air jet port 64 in a compressed state. The tight seal with the raised portion 72 is improved. The restoring force of the buffer member 8 accompanying the compression presses the duct surface portion 66a toward the raised portion 72, and increases the bonding force between the duct surface portion 66a and the raised portion 72. Accordingly, it is possible to prevent the foaming material m from entering the duct 6 from the air jet port 64 in the subsequent foam molding. In the configuration in which the buffer member 8 is in contact with the duct back surface portion 66b in a compressed state, the buffer member 8 is sandwiched between the upper mold 7b and the duct 6 disposed in the lower mold 7a by the mold closing. Therefore, no new equipment is required. The buffer member 8 is compressed by an autonomous action associated with the closing of the duct 6 disposed in the upper mold 7b and the lower mold 7a, and the tight sealing property between the duct surface portion 66a and the raised portion 72 is utilized by using the compression. Can be increased.

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 extremely difficult to integrally foam the seat pad 1 in which the duct 6 was embedded.
With respect to such a problem, the seat pad with the duct 6 and the method for manufacturing the same have the duct surface portion 66a surrounding the air jet port 64 by the mold closing, and the raised portion 72 that forms the recess 21. It is set as the structure which covers. The cushioning member 8 has a cushioning property as a structural characteristic, and air jets 64 (specifically, a duct surface portion 66a surrounding the air jets 64) distributed at each end of the duct 6 are provided. Eliminate dimensional errors. Even if a subtle dimensional error occurs in the contact state between the duct surface portion 66a and the raised portion 72, the cushioning member 8 is adaptively compressed in accordance with the dimensional error of each part due to its cushion characteristics, and the dimension is reduced. Absorb and resolve errors. 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, an annular recess 662 surrounding the air jet port 64 is provided in the duct surface portion 66a surrounding the air jet port 64, and the upper surface 722 of the raised portion closes the annular recess 662 by closing the mold. If it abuts on 66a, even if there is a gap between the upper end surface 722 of the raised portion and the duct surface portion 66a for some reason, it is possible to easily cope with the prevention of the foam raw material m from entering the air jet port 64 during foam molding. Even when the foaming material m enters the air outlet 64 during foam molding (enlarged view in the circle in FIG. 5), it once enters the annular recess 662, where the foaming 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. More specifically, the nozzle portion 65 is disposed so as to be close to the inner wall of the raised portion 72 that forms the hole 721, making it difficult for the foaming material m to pass through the gap ε. The foaming raw material m can be almost completely prevented from reaching. There is no problem even if there is a gap between the upper end surface 722 of the raised portion and the duct surface portion 66a due to insufficient compression of the buffer member 8 or an increase in foaming pressure during foam molding.
Even if the annular groove 723 is formed on the upper end surface 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 that is molded simply by 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, in the seat pad 1 with the duct 6 and the manufacturing method thereof, as described above, the foaming raw material m at the time of foaming the seat pad is made into the air jet port 64 by the cushioning member 8, the annular recess 662 and the annular groove 723. Intrusion into the inside of the duct 6 can be completely prevented, the work of removing the foaming material m that has entered the duct 6 is eliminated, and the yield is improved. Since the cushioning member 8, the annular recess 662, and the annular groove 723 improve the sealing performance of the air jet port 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.

  By the way, the seat pad 1 with the duct 6 is an integral foam molding of the seat pad 1, and the duct portion surrounding the air jet port 64 by the contact between the duct surface portion 66 a around the air jet port 64 and the raised upper end surface 722. Although the duct surface portion 66a of 66 is exposed, there is no particular problem. Since the seat pad 1 with the duct 6 covers the skin and becomes the seat cushion for the seat of the vehicle seat, it does not appear as a design surface and does not cause a problem. Further, even if there is a hardened portion of the foam raw material m that has entered the annular recess 662 or the annular groove 723 due to an increase in foaming pressure during foam molding, the skin is covered like the exposed portion of the duct surface portion 66a. Since it becomes a seat cushion for a seat portion of a vehicle seat, there is no problem at all. On the contrary, if the presence of the cured portion of the foaming raw material m that has entered the annular recess 662 or the annular groove 723 can be confirmed, the design numerical values such as the thickness and cushioning properties of the buffer member 8 are changed, and an early measure should be taken. Can do. The formation of the annular recess 662 and the annular groove 723 is effective in maintaining quality.

  Moreover, since the buffer member 8 backs and covers the duct 6, it helps to prevent the duct 6 from being damaged. In order to ensure cushioning of the seat pad 1, the duct 6 is disposed along the seat pad back surface 1b. However, if the duct 6 is exposed on the seat pad back surface 1b, There is a risk of damage due to interference with the foaming mold 7 or the frame when it is attached to a vehicle. The sheet-like back pad 8b of the buffer member 8 and the back surface 1b of the seat pad 1 form a uniform surface, and the seat pad 1 with the duct 6 in which the buffer member 8 comes into contact with the duct back surface portion 66b reduces the impact. The cushioning member 8 having cushioning properties protects the duct 6 and contributes to prevention of breakage. As in the embodiment, when the buffer member 8 is provided on the sheet pad back surface 1b side so as to cover the entire back surface side of the duct 6, it further protects the entire duct 6 and further contributes to prevention of breakage.

In addition, the presence of the buffer member 8 exhibits an excellent effect of suppressing noise prevention by the duct 6. Without the buffer member 8, the duct 6 is exposed on the seat pad back surface 1b side, or the back material of the nonwoven fabric 91 becomes the seat pad back surface 1b. The seat pad 1 with the duct 6 is attached to the vehicle and the position is adjusted. When traveling or running, abnormal noise may occur due to the duct 6 or the back material coming into contact with and rubbing the vehicle-side frame (or wire). Even if the back surface material of the nonwoven fabric 91 is present, since the hard duct 6 is present on the back side (sheet pad side) of the nonwoven fabric 91, abnormal noise is likely to occur.
On the other hand, the buffer member 8 has a cushioning property and has a plate-like thickness, and is disposed on the seat pad back surface 1b side in a compressed state, so that the abnormal noise generation can be effectively suppressed. . Since the cushioning member 8 has cushioning properties, the foaming material of the seat pad 1 is appropriately absorbed and impregnated with the foaming raw material m, and is in contact with the duct back surface portion 66b. It plays the role of loosening and softening the impact and impact from the frame (or wire) side to the duct 6 side. Generation of abnormal noise can be efficiently suppressed. In addition, if the buffer member 8 is a press felt, not only the impregnation and cushioning functions to ensure the sealing performance and noise prevention, but also the flexibility and flexibility required as a backing member for the duct 6 are provided. The seat pad 1 with the duct 6 that is more preferable in quality can be obtained.

  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 annular recess 662, the foaming die 7, the raised portion 72, the annular groove 723, etc. 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. In the present embodiment, a press felt having an impregnation property is used for the buffer member 8. However, it is sufficient that the buffer material 8 has a cushioning property capable of obtaining an effect of pressing the duct 6 against the raised portion 72 when the mold is closed. Even if it does not have impregnation properties, it can be held on the seat pad 1 by the nonwoven fabric 91 provided on the seat pad back surface 1b. Therefore, a gel-like member can be used as the buffer member 8. Further, in the present embodiment, the buffer member 8 is formed in a plate shape, but may be a block shape disposed only in the duct portion 66 in which the air ejection port 64 is formed. Further, in order to close the air jet port 64, the duct surface portion 66a around the air jet port 64 and the raised portion upper end surface 722 are brought into direct contact with each other, but a sealing material such as urethane foam may be sandwiched therebetween. The force pressing the duct 6 by the buffer member 8 also crushes the sealing material, making the sealing property even more reliable.

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 Introducing Portion 64 Air Jetting Port 66 Duct Portion 66a Duct Surface Portion 66b Duct Rear Portion 662 Annular Recess 7 Foaming Type 72 Raised Portion 722 Upper End Surface 8 Buffering Member 8b Plate Back Surface m Foaming Raw Material

Claims (8)

An air duct (6) provided with an air inlet (61) and an air outlet (64) in the duct path;
A cushioning member (8) having cushioning properties;
A recess (21) is formed on the surface (1a) on the passenger contact side, and the recess (21) becomes an air outlet (20) communicating with the air outlet (64). A duct (6), and a seat pad (1) integrally foamed by inserting the buffer member (8),
The buffer member (8) is embedded in the back surface (1b) side of the seat pad (1), and the buffer member (8) is a duct portion (66) in which the air jet port (64) is formed, A ducted seat pad characterized by being in contact with a duct back surface portion (66b) on the opposite side of the air jet port (64). The buffer member (8) has an impregnated plate shape, one plate surface of which contacts the duct back surface portion (66b), while the other plate surface on the opposite side is the seat pad (1). 2. The ducted seat pad according to claim 1, which forms a uniform surface with the back surface (1b). Further comprising a non-woven fabric (91), the non-woven fabric (91) covers the duct (6) including the cushioning member (8) and the duct back surface portion (66b), foam molding of the seat pad (1) The seat pad with duct according to claim 1 or 2, wherein the seat pad (1) is attached and integrated with the back surface (1b) of the seat pad (1). The seat pad with a duct according to any one of claims 1 to 3, wherein the buffer member (8) is a press felt. The duct portion (66) in which the air jet port (64) is formed, and an annular recess (662) surrounding the air jet port (64) is further formed in the duct surface portion (66a). The seat pad with a duct as described in any one of thru | or 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),
Along with the set of the air distribution duct (6) to the foaming mold (7), the cushioning member (8) having a cushioning property is set in the foaming mold (7), and then the mold is closed. By the duct portion (66) in which the air jet port (64) is formed, the buffer member (8) is brought into contact with the duct back surface portion (66b) on the opposite side of the air jet port (64) in a compressed state. Then, the air outlet (64) is closed by the raised portion (72) of the foaming mold (7) forming the recess (21), and then the cushioning is performed by foam molding of the seat pad (1). A method for producing a ducted seat pad, wherein the member (8) is embedded and integrated on the back surface (1b) side of the seat pad (1). An annular recess (662) surrounding the air jet port (64) is further provided in the duct surface portion (66a) surrounding the air jet port (64), and the upper end surface of the raised portion (72) is closed by mold closing ( The method of manufacturing a seat pad with a duct according to claim 6, wherein 722) contacts the duct surface portion (66a) so as to close the annular recess (662). An annular groove (723) is further formed on the upper end surface (722) of the raised portion (72) that abuts on the duct surface portion (66a) surrounding the air jet port (64). The method for producing a ducted seat pad according to claim 6, wherein (66a) contacts the upper end surface (722) of the raised portion (72) so as to block the annular groove (723).

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