JP2013193581A - Rear seat pad and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rear seat pad which contributes to the improvement of riding comfort and safety by preventing an occupant from shifting rearward due to rear-end collision or the like, the occupant sitting on a middle seat in a vehicle width direction of a rear seat for a vehicle, and a manufacturing method therefor.SOLUTION: A rear seat pad 1 of a rear seat for a vehicle consists of a massive chip member 3 which is buried in a seat pad portion W2 constituting a middle seat in a vehicle width direction and in a raised part 12 which is bulged upward in a vehicle longitudinal direction from a rear end of a flat part 11 for a seat part having a substantially flat upper surface and gets into a part under a backrest BR so as to force a surface 3a thereof to conform to the bulged surface 12a by making the hardness thereof greater than that of the flat part 11 and securing the thickness from the bulged surface 12a of the raised part 12 to a raised part thickness direction, and of a pad body 2 which is formed by inserting the chip member 3 therein and integrally foam-molding the flat part 11 and the raised part 12 around the chip member 3.

Description

  The present invention relates to a rear seat pad constituting a rear seat for a vehicle such as a passenger car and a method for manufacturing the rear seat pad.

  A vehicle seat such as an automobile is provided with a seat for a passenger to sit on and a backrest for a backrest, and a seat cushion as a seat portion of the seat is a seat pad covered with a skin. A cushion member such as a flexible polyurethane foam is used for this seat pad, but several different hardness seat pads having different hardnesses have been proposed so far in pursuit of comfort (for example, Patent Document 1). ~ 3).

JP-A-1-238910 JP 58-209385 A JP-A-9-225951

However, the conventional seat pad-related inventions including Patent Documents 1 to 3 soften the surface part of the seat pad in order to make the side part harder than the main part of the seat pad or to relieve the pressure received from the seat pad when seated. Many eyes were directed to the tasks to be done.
Under these circumstances, the present inventors, during the rear-end collision test evaluation, in the rear seat for a vehicle such as a three-seater passenger car, the occupant sitting in the middle in the vehicle width direction compared to the occupant sitting in the general seat on both sides in the vehicle width direction during the rear-end collision, I discovered a new fact that the amount of shift to the rear of the vehicle increases. The seat in the middle in the vehicle width direction usually has few passengers sitting, but if a passenger sits in the middle with three people, the collision test evaluation shows that it moves more backward in the vehicle than the passenger in the general seat at the time of collision. I understand.

  Referring to FIGS. 12 to 14, the seat pad 9 </ b> B of a general seat has a raised portion extending below the backrest BR from the rear end of the seat portion. The seating surface of the main portion 91 forms a curved surface as shown in FIG. 13, and the height α from the seating surface to the upper surface of the raised portion 98 can be sufficiently secured. On the other hand, even in the seat in the middle in the vehicle width direction, the raised portion 97 extends below the backrest BR from the rear end of the seat portion of the seat pad 9A. However, since the seat pad 9A in the middle often has an armrest, the seat pad 93 has a flat upper surface. Therefore, the height β from the seat portion 93 to the upper surface of the raised portion 97 is lower than the height α of the general seat. That this height is not sufficient causes a problem that the rear seat moves more backward than a general seat due to the occurrence of a rear-end collision or the like.

  The present invention solves the above-mentioned problem and contributes to improving the ride comfort and safety by suppressing the occupant sitting in the middle seat in the vehicle width direction of the rear seat of the vehicle from moving backward due to a rear-end collision or the like. It is an object of the present invention to provide a rear seat pad and a manufacturing method thereof.

In order to achieve the above object, the gist of the invention described in claim 1 is that in the rear seat pad (1) of the rear seat for the vehicle, the seat pad portion (W2) constituting the seat in the middle in the vehicle width direction and the front and rear of the vehicle The raised portion (12) that rises upward from the rear end of the seat flat portion (11) whose upper surface is substantially flat in the direction and enters under the backrest (BR) is made harder than the hardness of the flat portion (11). In addition, a lump chip member (3) having a thickness from the raised surface (12a) of the raised portion (12) in the raised portion thickness direction and embedded in conformity with the surface (3a) of the raised portion surface (12a) And insert the tip member (3), the pad body (2) formed by integral foam molding the flat portion (11) and the raised portion (12) around the tip member (3) And a rear seat pad. A rear seat pad according to a second aspect of the present invention is the rear seat pad according to the first aspect, wherein the tip member (3) is made of a foam and further has a size that reaches from the front surface (12a) of the raised portion (12) to the rear surface of the raised portion (12b). The chip member surface (3a) occupies a part of the ridge part surface (12a) and the chip member back surface (3b) occupies a part of the ridge part back surface (12b), and the chip member (3) is flat. The pad main body (2) surrounds the four sides of the view, and is integrally foam-molded. A rear seat pad according to a third aspect of the present invention is the rear seat pad according to the first or second aspect, wherein the pad main body (2) is formed by foaming using the foaming raw material (f), and the rear surface pad (3b) side of the chip member (3) is also formed. Further comprising a sheet-like backing member (4) that is attached to and integrated with the chip member back surface (3b) and the pad main body back surface (2b) by interposing the foaming raw material (f) as an adhesive. And A rear seat pad according to a fourth aspect of the present invention is a flexible sheet-like piece formed of a foam having a lower hardness than the chip member (3) and covering the surface (3a) of the chip member. A cushion member (5) is further provided. A rear seat pad according to a fifth aspect of the present invention is the rear seat pad according to the second to fourth aspects, wherein the side wall surfaces (32 to 34) around the four sides in a plan view of the chip member (3) surrounded by the pad body (2) are subjected to a surface treatment. The rough surface is formed.
The gist of the invention described in claim 6 is that in the manufacturing method of the rear seat pad (1) of the rear seat for a vehicle, the foaming mold (6) that forms the cavity (CA) of the rear seat pad by closing the mold, Seat pad part (W2) that constitutes the seat in the middle of the vehicle width direction, and rises upward from the rear end of the seat flat part (11) whose upper surface is substantially flat in the vehicle front-rear direction and below the back pad (BP) On the mold surface (7a) according to one split mold (7) corresponding to the raised part (12) to enter, while setting the chip member (3) molded in advance harder than the hardness of the flat part (11) Then, set the sheet-like backing member (4) on the mold surface (8a) of the other split mold (8), and then inject the foam raw material (f) including the back surface (3b) side of the chip member (3). Thereafter, the mold is closed, and then the chip member surface (3a) is exposed to the raised surface (12a), and the chip member back surface (3b) is the backing member (4) together with the pad body back surface (2b). So as to be deposited, in the manufacturing method of the rear seat pad characterized by foam molding a pad body (2) for embedding integrated the tip member (3).

As in the first and sixth aspects of the invention, the lump is embedded with a thickness in the thickness direction from the raised surface (12a) of the raised portion (12) that is harder than the hardness of the flat portion (11). If the tip member is provided, since the hardness of the tip member increases, the role of the stopper for receiving the occupant's buttocks is enhanced, so that the buttocks are not displaced rearward due to a rear-end collision or the like. Even if the height from the flat part to the upper surface of the raised part is low, the tip member having a thickness from the raised surface (12a) of the raised part (12) to the raised part thickness direction is hard, so the seat in the middle in the vehicle width direction It is possible to prevent the buttock of the occupant sitting on the side from shifting backward. When the chip member is inserted and the pad main body (2) is formed by integral foam molding of the flat portion (11) and the raised portion (12) around the chip member, the pad main body and the chip member are configured separately. The tip member is responsible for adjusting the hardness in the vehicle front-rear direction around the raised portion, and the pad main body only needs to be adjusted in the vehicle width direction and the vehicle vertical direction, so that the hardness adjustment of the pad main body becomes easy.
As in the invention of claim 2, the tip member surface occupies a part of the raised portion surface (12a) and has a size reaching the raised portion rear surface (12b) from the surface (12a) of the raised portion (12). If the back surface occupies a part of the back surface of the raised portion (12b), it replaces the thick layer of the raised portion where the tip member is embedded, and the sinking of the tip member to the back side of the raised portion is eliminated, so the occupant's buttocks Can be taken. When the pad main body (2) surrounds the periphery of the chip member in four directions in plan view and is integrally foamed, the joint surface between the chip member and the pad main body is in the periphery of the four sides, so that the integration between the two becomes strong. When the backing member is provided as in the invention of claim 3, the integration of the chip member and the pad main body becomes stronger. When the cushion member (5) is provided as in the fourth aspect of the invention, the tip member can be prevented from shifting backward in a rear-end collision and the like, and the cushion member can be responsible only for comfort when seated. Both safety and comfort can be easily pursued. When the side wall surface of the chip member surrounded by the pad main body is roughened as in the fifth aspect of the invention, the foam material is easily impregnated into the chip member during foam molding, and the bonding force between the pad main body and the chip member is increased.

  The rear seat pad and the manufacturing method thereof according to the present invention can prevent a passenger from slipping backward even if an occupant sits in the middle seat in the vehicle width direction of the rear seat of the vehicle and a sudden start or rear-end collision occurs. Excellent effect on comfort and safety.

It is a top view of the rear seat pad concerning the present invention. It is the schematic perspective view which looked at the rear seat pad of FIG. 1 from the surface side. It is the III-III arrow directional view of FIG. It is the schematic perspective view which looked at the rear seat pad of FIG. 1 from the back surface side. It is the perspective view which looked at the chip member from the back side. It is sectional drawing of the rear seat pad which covered the plate-shaped cushion material on the chip | tip member surface of FIG. It is explanatory drawing sectional drawing of the foaming type | mold which is inject | pouring the foaming raw material after setting a chip | tip member and a backing material in a mold open state. It is explanatory sectional drawing of the foaming mold which mold-closes and goes to foam molding. It is explanatory sectional drawing which finished the foam molding of the pad main body. It is explanatory sectional drawing which covers the cushion member of another aspect which replaces the cushion member of FIG. 6 on the chip | tip member surface. (A) is a perspective view of the chip member of the other aspect which replaces the chip member of FIGS. 1-5, (b) is explanatory sectional drawing which carried out the die surface setting of the chip member of (b). It is a schematic perspective view of the conventional seat pad. FIG. 13 is a view taken along line XIII-XIII in FIG. 12. (A) is a longitudinal cross-sectional view of the seat pad for general seats in the longitudinal direction of the vehicle, and (b) is a longitudinal cross-sectional view of the seat pad portion for the center seat in the longitudinal direction of the vehicle.

  Hereinafter, the rear seat pad and the manufacturing method thereof according to the present invention will be described in detail. 1 to 11 show one embodiment of the rear seat pad and the manufacturing method thereof according to the present invention, FIG. 1 is a plan view thereof, FIG. 2 is a front side perspective view of the rear seat pad, and FIG. 3 is a view taken along line III-III in FIG. 4 is a rear perspective view of the rear seat pad, FIG. 5 is a rear perspective view of the chip member, FIG. 6 is a sectional view of the rear seat pad in which the chip member surface of FIG. 3 is covered with a cushion material, and FIG. FIG. 8 is a cross-sectional view of a foaming mold for injecting a foaming raw material after setting the backing material, FIG. 8 is a cross-sectional view of the foaming mold toward the foam molding after closing the mold, and FIG. 9 is a cross-sectional view of the pad main body after the foam molding. FIG. 10 is an explanatory view of a cushion member according to another aspect, and FIG. 11 is an explanatory view of a tip member according to another aspect. In order to make the drawing easy to understand, the backing member omits hatching representing a cross section.

(1) Rear seat pad The rear seat pad 1 is a cushion pad that receives and supports the lower half of the seated occupant M. The present embodiment is applied to a rear seat pad of a three-seat rear seat such as a passenger car and a rear seat pad that forms a general seat on the right side in the vehicle traveling direction and a seat in the middle in the vehicle width direction as shown in FIGS. Here, with reference to FIG. 1, the vehicle traveling direction refers to the downward direction of the paper, the vehicle width direction refers to the horizontal direction of the paper surface, and the upward direction refers to the upward direction of the paper surface.
In the seat arrangement, the rear seat pad LF of the general seat on the left side in the vehicle traveling direction is separated. If the rear seat pad LF of the left general seat is added and the two rear seat pads 1 and LF are covered with the skin S to form a seat cushion, a known backrest BR and a known headrest form a vehicle rear seat. . Reference numerals 14 and 15 denote vertical grooves and horizontal grooves for the skin set, and reference numeral 10 denotes a dividing groove. Reference numeral 13 denotes a seat belt mounting step, and FIG.
The rear seat pad 1 includes a chip member 3, a pad body 2, and a backing member 4.

The outer shape of the rear seat pad 1 is publicly known, and as shown in FIGS. 1 and 2, a seat pad portion 1B for a general seat on the right side in the vehicle traveling direction (hereinafter also simply referred to as “right seat pad portion”), and the middle in the vehicle width direction. A seat pad portion 1A for the center seat (hereinafter, also simply referred to as “center seat pad portion”) of the seat pad portion W2 constituting the seat.
The right seat pad portion 1B includes a main portion 16a that supports the buttock MH and thigh TH of the lower occupant seated on the seat portion 16, and a side portion that supports the side portions of the buttock MH and thigh TH on both sides of the main portion. 16b. The XIV-XIV line arrow view of FIG. 2 has the same outer shape as FIG. 14 (a), and a raised portion 17 that rises upward from the rear end of the main portion 16a and enters under the backrest BR extends.
On the other hand, the center seat pad portion 1A has a substantially flat upper surface in the vehicle front-rear direction and the seat flat portion 11 on which the occupant MH of the occupant M rests, and extends from the rear end, and rises upward and below the backrest BR. And a raised portion 12 to enter (FIG. 3). When the number of occupants is small, it does not normally sit on the flat portion 11. Since the armrest is often placed, the upper surface is a flat portion 11 that is substantially flat. On the other hand, when the number of occupants increases and the rear seat is a three-seater seat, the armrest is housed in the backrest BR, and the seat flat portion 11 on which the occupant's buttocks MH rests. The height β from the seating surface 110 that is the upper surface of the flat portion 11 to the upper surface (the highest point) of the raised portion 12 is the same as in FIG. 12, from the seating surface of the main portion 16a according to the right seat pad portion 1B to the upper surface of the raised portion 12. Is lower than the height α.

  As shown in FIG. 1, the right seat pad part W1, the center seat pad part W2, and the left seat pad part W3 are arranged in the vehicle rear seat in the vehicle width direction, and the seat part region L1 faces the rear of the vehicle at each part. The rear seat pad product is arranged so that the raised region L2 extends. For this product, the tip member 3 of the present invention is provided in the center sheet pad portion W2 and the raised region L2 where it is difficult to sufficiently secure the height β.

  The chip member 3 is a block member that is harder than the hardness of the flat portion 11 and is embedded with a thickness from the raised surface 12a of the raised portion 12 in the thickness direction of the raised portion 12. This is an insert member that is separately manufactured in advance by making the raised portions 12 other than the flat portion 11 and the chip member 3 harder than the hardness of the pad main body 2 made by foam molding. The chip member 3 is formed by foaming of the pad main body 2 and is embedded and integrated in the raised portion 12 with its surface 3a being exposed in accordance with the raised portion surface 12a.

The chip member 3 of the present embodiment is a molded product made of a foam, and is a board-like urethane chip material as shown in FIGS. The rectangular body is formed into a bent shape that matches the raised curved surface of the raised portion 12, and the vehicle rear corner is made into a rectangular shape in plan view in FIG. And the notch parts 35-37 are provided in three places (plural places) of the four-way side wall of this chip member 3, and step part 35d-37d is provided near the chip member surface 3a in each notch part.
Here, the tip member 3 is set to have a hardness higher than that of the flat portion 11, but the density can be controlled because the flat portion 11 is also a urethane material (described later). The higher the hardness, the higher the density, and the chip member 3 has a higher density than the flat portion 11.

  The tip member 3 is sized to reach the raised portion back surface 12b from the surface 12a of the raised portion 12, and the surface 3a occupies a part of the raised portion surface 12a, and the tip member back surface 3b is the height of the raised portion back surface 12b. Occupies a part. The thickness of the tip member 3 is equal to the thickness of the raised portion 12 where the tip member 3 is embedded, and a part of the thickness layer related to the raised portion (reference numeral 97 in FIG. 14) of the conventional product is replaced with the tip member 3. The tip member 3 is a raised portion 12 of the seat pad portion W2 constituting the seat in the middle in the vehicle width direction, and has a width WD that leaves both ends 122 in the vehicle width direction, and the pad body 2 is surrounded by the pad body 2 in a plan view.

  Further, the tip member 3 forms a rising surface 31 in accordance with the raised portion 12 that rises from the rear end of the flat portion 11 (FIG. 2), starts from here toward the rear of the vehicle, and the tip member surface 3a has a height β. It reaches the upper surface (the highest point) of the raised portion 12 that forms The figure in which the tip member reaches about a half point of the length in the vehicle front-rear direction of the raised portion 12 from the rising surface 31 at the raised portion 12 connected to the rear end of the flat portion 11 while occupying the central region in the vehicle width direction. The size is 1 in plan view.

As described above, the tip member 3 occupies the entire thickness direction of the raised portion 12 at the place where the tip member 3 is disposed on the raised portion 12. Not only the surface 3a of the chip member 3 becomes the raised surface 12a, but also the back surface 3b of the chip member 3 becomes the raised surface 12b. The tip member 3 in FIG. 5 is manufactured with its thickness corresponding to the thickness of the raised portion 12. However, in order to avoid a situation in which the tip member 3 is caught by the locking members 75 to 77 and cannot be taken out together with the pad main body 2 at the time of demolding, the vehicle rear side wall surface 33 of the tip member 3 is formed on the raised surface 12a. A slope is formed by inclining from the side toward the rear surface 12b toward the vehicle rear side (FIG. 3). The both side wall surfaces 34 of the tip member 3 in the vehicle width direction are slightly inclined outward from the vehicle from the raised surface 12a side to the back surface 12b side to form inclined surfaces.
Furthermore, the chip member 3 performs uneven surface treatment on the side wall surfaces (the vehicle front side wall surface 32, the vehicle rear side wall surface 33, and the vehicle width direction side wall surface 34) which are connection surfaces with the pad main body 2. Fine irregularities are formed on the side wall surfaces 32 to 34 to form a rough surface RH. By subjecting the side wall surfaces 32 to 34 around the four sides in the plan view surrounded by the pad main body 2 to an uneven surface treatment, the foam raw material f is easily impregnated into the chip member 3 during foam molding, and the chip member 3 The bonding strength to the pad body 2 increases. By foam molding, the integration with the pad main body 2 is strengthened, and it is more reliably taken out together with the pad main body 2 at the time of demolding.

The pad body 2 is a foam molded product in which a chip member 3 is inserted using a foamed resin raw material such as a polyurethane material, and a flat portion 11 and a raised portion 12 around the chip member 3 are formed by integral foam molding. Yes (FIGS. 1-3). The chip body 3 is inserted to form a pad body 2 in which not only the center seat pad portion 1A but also the right seat pad portion 1B is integrally foam-molded. A main portion 16a, a side portion 16b, and a raised portion 17 for the right seat pad portion 1B are formed. On the other hand, in the center seat pad portion 1A, the pad main body 2 forms the flat portion 11 for the seat portion and the raised portion 12 around the chip member 3 by foam molding. The pad body 2 in which the chip member 3 is embedded and the raised surface 12a is aligned with the surface 3a is foam-molded. In addition, the pad main body 2 is made to be flush with the chip member back surface 3b by combining the raised portion back surface 12b.
Then, the backing member 4 is integrally attached to the rear seat pad rear surface 1b by foam molding of the pad main body 2 of the present embodiment.

The backing member 4 is a foam molding of the pad main body 2 using the foam raw material f, and the foam raw material f is interposed on the back surface 3b side of the chip member 3 as an adhesive so that the chip member back surface 3b and the pad main body back surface 2b are interposed. It is a sheet-like body to be adhered and integrated. The backing member 4 is made of a nonwoven fabric or the like, and has a size covering substantially the entire area of the rear seat pad back surface 1b as shown in FIGS. The backing member 4 suppresses the generation of abnormal noise due to contact with the frame that supports the rear seat pad 1 from below. Further, the backing member 4 is integrally attached to the pad main body back surface 2b and the chip member back surface 3b, and is a desired rear seat pad 1 that further strengthens the integration of the pad main body 2 and the chip member 3.
The back surface 12b of the raised portion 12 referred to in the present invention is the back surface 12b of the raised portion formed by the pad body 2 and the chip member 3 excluding the backing member 4 when the backing member 4 is present.

FIG. 6 shows another embodiment of the rear seat pad 1 in place of FIGS. The surface 3a of the chip member 3 related to the rear seat pad 1 of FIGS. 1 to 5 is a rear seat pad 1 covered with the plate-like cushion member 5 by further post-processing. The cushion member 5 is formed of a plate-like foam such as a slab sheet whose hardness is lower than that of the chip member 3, and is covered on the chip member surface 3a side. To prevent the occupant M sitting on the flat part 11 from being displaced rearward, the tip member 3 is increased in hardness, and the cushion member 5 is provided with comfort such as cushioning of the occupant M sitting on the flat part 11. Let them share their roles. The desired rear seat pad 1 that pursues further comfort is finished.
Here, as shown in FIG. 10, the cushion member 5 is provided with a pin-like protrusion 52 on the back surface 5 b, and the chip member 3 is covered with the cushion member and provided with a notch 39 at a position facing the protrusion 52. It becomes preferable. The protrusion 52 is positioned, and the cushion member 5 can be easily attached to the chip member 3. The protrusion 52 may be integrated with the cushion member main body 51 or may be separate.

  Further, as another embodiment of the chip member 5 of FIGS. 1 to 5, for example, the chip member 5 of FIG. The chip member 5 is formed with a recess 38 having a substantially circular cross section in the chip member surface 5a instead of the notches 35 to 37 in FIG. 5, while the foaming die 6 (described later) used for the manufacturing method of the rear seat pad includes A rod-like body 78 that is slightly larger than the cross-sectional shape of the recess 38 is erected on the mold surface 7 a on which the chip member 5 is set. The depression 38 here includes a through hole as shown in FIG. In FIG. 11, a rod-like body 78 having a threaded portion 781 is formed, and the rod-like body 78 is inserted into a recess 38 provided substantially at the center of the chip member 5 to set the chip member 5 on the mold surface 7 a. Therefore, the chip member 5 can be easily attached to and removed from the foaming mold 1. The notches 35 to 37 in FIG. 5 engage the tip member with the under portions of the hook-like engaging members 75 to 77, but the tip is caused by the friction of the threaded portion 781 of the rod-like body 78 inserted into the recess 38 in FIG. This is because the member 5 can be locked.

(2) Manufacturing method of rear seat pad The manufacturing method of the rear seat pad 1 uses the chip member 3, the backing member 4, and the foaming mold 6, and after setting the chip member 3 and the backing member 4 to the foaming mold 6, The rear seat pad 1 as shown in FIGS. 1 to 4 is formed through injection of the foaming raw material f and mold closing.
The chip member 3 and the backing member 4 are the same as those described in the rear seat pad 1 of (1), and details thereof are omitted.

The foaming mold 6 used in the manufacturing method of the rear seat pad 1 is a divided mold as shown in FIGS. 7 to 9 and includes a lower mold 7 (one divided mold) and an upper mold 8 (another divided mold). Reference numeral HG indicates a hinge. When the mold is closed as shown in FIGS. 7 to 8 with the hinge HG as a fulcrum, the chip member 3 is embedded in the mold surface 7a of the lower mold 7 and the mold surface 8a of the upper mold 8, and the backing member 4 is attached. A cavity CA of the rear seat pad 1 to be integrated is created. On the mold surface 7a on which the chip member 3 of the lower mold 7 is set, hook-shaped locking members 75 to 77 as shown in FIG. 5 are provided, and the chip member 3 can be locked and held. 7 to 9, the front surface 1a side of the rear seat pad 1 is molded by the mold surface 7a of the lower mold 7, and the rear surface 1b side of the rear seat pad 1 is molded by the mold surface 8a of the upper mold 8. Reference numeral 7a ₁ is a surface side mold surface of the flat portion 11, reference numeral 7a ₂ is a front surface mold surface of the raised portion 12, reference numeral 8a ₁ is a back surface side mold surface of the flat portion 11, and reference numeral 8a ₂ is a back surface side mold of the raised portion 12. Show the surface.

The rear seat pad 1 is manufactured as follows, for example, using the foaming mold 6, the chip member 3, and the backing member 4 of FIGS.
First, the foaming mold 6 is brought into the mold open state. Next, the chip member 3 is set on the lower mold 7 in this mold open state, and the backing member 4 is set on the upper mold 8 (FIG. 7). The lower die corresponding to the raised portion 12 that rises upward from the rear end of the seat flat portion 11 and enters under the backrest BR with the surface 3a projecting from the chip member 3 as the lower die surface 7a side. It is arranged on the mold surface 7a. Then, reverse side L-shaped hook-like locking members 75 to 77 standing on the mold surface 7a are fitted into the notches 35 to 37 (FIG. 5), and the projecting ends 75e to 77e of the locking members are stepped 35d. The chip member 3 is locked and set on ~ 37d. The rising surface 31 of the chip member 3 is standing upright on the lower mold surface 7a. The backing member 4 is attached and set to the upper mold surface 8a with a locking tool (not shown).

  Subsequently, a predetermined amount of a foaming raw material f such as a urethane foam stock solution for the pad main body 2 is injected using an injection hose N or the like while the mold is open. Here, the foaming raw material f including the back surface 3b side of the chip member 3 is injected. In addition to the mold surface 7a of the bowl-shaped dent forming the cavity of the lower mold 7, a small amount of foaming raw material f is poured also into the chip member back surface 3b as shown by a chain line in FIG.

  Thereafter, the upper mold 8 is operated to close the mold (FIG. 8). With this mold closing, a rear seat pad cavity CA into which the chip member 3 is inserted is formed. At the same time, the backing member 4 is set on the upper mold surface 8a, and the backing member 4 and the chip member 3 are bonded with the foaming raw material f interposed therebetween, and the foaming raw material poured into the chip member back surface 3b. The surplus of f flows out from the chip member back surface 3b to the cavity CA as shown by the arrow in FIG.

After the mold closing, the process proceeds to foam molding of the pad body 2. 8 is maintained for a predetermined time, and the pad body 2 in which the chip member 3 is embedded and integrated is foamed to form the rear seat pad 1 (FIG. 9).
Here, as described above, the side wall surfaces 32 to 34 of the chip member 3 that are in contact with the bonding surface with the pad main body 2 are subjected to surface treatment in a concavo-convex shape to form a rough surface RH. In the foam molding process, the chip member 3 is easily impregnated with the urethane raw material f, and the bonding strength between the chip member 3 and the pad main body 2 is increased.

When foam molding of the pad body 2 is completed and removed, the chip member surface 3a is exposed to the raised surface 12a, and the chip member back surface 3b is attached to the backing member 4 together with the pad body back surface 2b. Pad 1 is obtained.
A hard tip member 3 is embedded in the raised portion 12 where the height β cannot be sufficiently obtained, and the displacement of the occupant's buttocks MH to the rear of the vehicle is suppressed. The tip member 3 enters the lateral groove 15 at the vehicle front start point at the boundary between the flat portion 11 and the raised portion 12 as shown in FIG. Further, the tip member 3 that forms the rising surface 31 that covers the entire height β of the raised portion serves as a displacement prevention member for the occupant's collar MH. The urethane foam raw material f is interposed as an adhesive also on the back surface 3b side of the chip member 3, and a desired rear sheet pad 1 in which the backing member 4 is integrally attached not only to the pad main body back surface 2b but also to the chip material back surface 3b. It has become. A small hole 126 which is a trace of the locking member 76 to which the chip member 3 is set and fixed appears in the raised portion 12, but there is no problem because it is covered with the skin S.
When the rear seat pad 1 is covered with the skin S (FIG. 3), it becomes a rear seat cushion of the rear seat for the vehicle.

More preferably, the surface 3a of the chip member 3 is covered with a plate-like cushion member 5 formed of foam such as a slab sheet as shown in FIG. Since the cushion member 5 covers the hard tip member 3 to which the buttocks MH come into contact, the rear seat pad 1 that further improves the riding comfort is completed. In addition, when the protrusion 52 is provided on the cushion member 5 as shown in FIG. 10 and the notch 39 is provided on the chip member 3, these serve to position and easy attachment and covering of the cushion member 5 to the chip member 3 is possible. become.
Further, the tip member 5 as shown in FIG. 11 is employed, and the rod-shaped body 78 can be used in the foaming mold 6 instead of the hook-shaped locking members 75 to 77. In such a case, the recess 38 is inserted into the rod-like body 78 as shown by the arrow in FIG. 11 (a), and the chip member 3 is inserted as shown in FIG. 11 (b). The tip member 3 is locked and set to the lower mold 7 by the friction of the threaded portion 781. Since the tip member 3 is set on the curved surface forming portion of the raised portion 12 as shown in the figure, even if only one recess 38 is provided near the center of the tip member 3, it is set and fixed without rotating. Even if the chip member 5 of FIG. 11 is used, the steps after the setting are the same as those of FIGS.

(3) Effect The rear seat pad 1 configured as described above has a higher height β from the seating surface 110 of the flat portion 11 to the upper surface of the raised portion 12 than the hardness of the flat portion 11 in the raised portion 12. Since the hardened lump chip member 3 is embedded, this becomes a stopper, and it is possible to stop the occupant's heel part MH sitting on the flat part 11 from being greatly displaced rearward at the time of sudden start or rear-end collision. When the tip member 3 having a thickness in the thickness direction of the raised portion 12 from the raised surface 12a of the raised portion 12 is used, the tip member 3 is applied to the raised portion surface 12a that directly acts to stop the occupant M from moving backward. Therefore, it is effective for preventing the passenger M from moving backward.
Furthermore, when the tip member surface 3a occupies a part of the bulge part surface 12a and the chip member back surface 3b occupies a part of the ridge part back surface 12b, the size reaches the ridge part back surface 12b from the surface 12a of the ridge part 12. In this case, the entire thickness direction of the raised portion 12 is filled with the hard tip member 3. As a result, even if the occupant's buttocks MH sitting on the flat part 11 at the time of rear-end collision try to move backward, the sinking at the tip member 3 is remarkably suppressed as compared with the one made with the conventional pad body, The rearward movement of the flange MH (the white arrow in FIG. 3) can be reliably prevented. If the raised portion 12 does not have the required hardness and is soft, the raised portion height β is low, and the entire portion sinks. On the other hand, in the rear seat pad 1, since the tip member 3 fills the entire thickness direction of the raised portion 12, there is no sinking even at a low height β, and the rearward movement of the buttocks can be almost completely prevented.

In addition, when the chip member 3 is inserted and the pad main body 2 is integrally foamed, the chip member 3 becomes a separate product, so that the chip member 3 having the required hardness can be easily prepared and procured. When the tip member 3 is responsible for adjusting the hardness in the longitudinal direction of the vehicle, the pad body 2 can concentrate on adjusting the hardness in the vehicle height direction (or / and the vehicle width direction), so that the hardness adjustment of the pad body is very much. It will be easier and will lead to quality improvement. If the hardness in the vehicle front-rear direction is kept constant, adjustment in the vehicle height direction is facilitated, and man-hours can be reduced.
Here, it is also conceivable to change the hardness and density of only the portion of the tip member by injecting another blended raw material into the tip member corresponding portion using a multi-point shot without the tip member 3. However, it takes time to adjust the hardness in the vehicle height direction (or / and the vehicle width direction), and when the tip member 3 is omitted, the hardness adjustment in the vehicle longitudinal direction is added, which is extremely difficult. Furthermore, even if only the part of the chip member 3 is changed by in-mold foaming, the boundary cannot be made clean, which is very difficult in terms of technology and manufacturing. The injection of the foaming raw material f is not stable, and the foaming raw material f turns to a place where it is not desired to change the hardness during foaming, and the hardness is not stable. Moreover, when the volume is small, such as the tip member 3, there are limits to the hardness setting and density setting. In a thin portion such as the raised portion 12 where the tip member 3 is disposed, it is particularly difficult to adjust the hardness and the injection amount. According to the present invention, the tip member 3 is separated and the hardness and density are adjusted. Because it is easy to manufacture, it has a tremendous effect in this rear seat pad that requires countermeasures against pinpoints. In the present invention, it is possible to easily make a separate hardness member 3 having a different hardness according to the required hardness, density and shape as an insert member at a necessary portion of the raised portion 12 where the flange portion MH hits, and the foaming die 6. The target rear seat pad 1 can be easily manufactured by setting the chip member 3 to the front. It is excellent in terms of cost and quality. A tip member having the required hardness and density and the required size can be appropriately pinpointed at the required ridge 12 so that the height of the occupant M sitting on the center seat can be reduced. A quality rear seat pad 1 can be obtained.

In addition, if the tip member 3 is made of a foam, some cushioning properties remain even if it has the required hardness. Even if the occupant's buttocks MH hit the tip member 3 embedded in the raised portion 12, there is no sense of incongruity. Further, when the chip member 3 is made of a foam, it can be somewhat deformed, and even if the chip member 3 is locked and set with the hook-shaped locking members 75 to 77, demolding after foam molding becomes easy.
Further, regarding the above manufacturing method, if the rod-like body 78 is inserted into the recess 38 of the tip member 3, the tip member 3 can be locked by the friction of the screw cutting portion 781, so that the notches 35 to 37 and the locking members 75 to 77 are fixed. In comparison, the setting of the chip member 3 to the lower mold 7 and the product demolding can be performed more smoothly.

When the pad main body 2 is formed by integral foaming of the raised portion 12 around the chip member 3, the chip member 3 and the pad main body 2 can be firmly integrated. When the side wall surfaces 32 to 34 of the chip member are formed into a rough surface, the urethane raw material f enters the unevenness of the rough surface RH to produce a throwing effect, and the chip member 3 is easily impregnated. Bonding integration becomes stronger. Since the tip member surface 3a appears on the raised surface 12a, the check of whether or not the tip member 3 is inserted at the time of demolding proceeds smoothly.
When the cushion member 5 covering the chip member surface 3a is provided, the cushioning property can be pursued by the cushion member, and if the protrusion 52 and the notch 39 are further provided, the cushion member 5 can be easily attached to the chip member 3.
Thus, this rear seat pad exhibits a number of excellent effects and is extremely beneficial.

  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 flat portion 11, the raised portion 12, the pad main body 2, the chip member 3, and the like can be appropriately selected according to the application. For example, a rear seat pad in which the rear seat pad LF of the left general seat is integrated with the rear seat pad 1 of the first embodiment may be used.

DESCRIPTION OF SYMBOLS 1 Rear seat pad 11 Flat part 12 Raised part 12a Raised part surface (surface)
12b Bump back side (back side)
2 Pad body 2b Back side of pad body (back side)
3 Chip member 3a Chip member surface (surface)
3b Chip member back side (back side)
4 Backing member 5 Cushion member 6 Foaming type 7 One split type (lower type)
7a Mold surface 8 Other split mold (upper mold)
8a Mold surface BR Backrest CA Cavity W2 Seat pad part constituting the seat in the middle in the vehicle width direction f Foaming material

Claims (6)

In the rear seat pad (1) of the rear seat for vehicles,
The seat pad part (W2) that constitutes the seat in the middle in the vehicle width direction and rises upward from the rear end of the flat part (11) for the seat part whose upper surface is substantially flat in the vehicle front-rear direction and below the backrest (BR) The ridge portion (12) that enters into the ridge portion (12) is harder than the hardness of the flat portion (11), and has a thickness in the ridge portion thickness direction from the raised surface (12a) of the ridge portion (12). A bulky chip member (3) embedded in conformity with the raised surface (12a)
Inserting the tip member (3), the flat body (11) and the raised portion (12) around the tip member (3), a pad body (2) formed by integral foaming; and
A rear seat pad comprising: The tip member (3) is made of foam, and the tip member surface (3a) has a size that reaches the raised portion back surface (12b) from the surface (12a) of the raised portion (12), and the tip member surface (3a) is the raised portion surface (12a). The chip member back surface (3b) occupies a part of the raised portion back surface (12b), and the pad body (2) surrounds the chip member (3) in a plan view and surrounds it. The rear seat pad according to claim 1, which is foam-molded. In foam molding of the pad main body (2) using a foaming raw material (f), the foaming raw material (f) is also interposed as an adhesive on the back surface (3b) side of the chip member (3), and the back surface of the chip member The rear seat pad according to claim 2, further comprising: a sheet-like backing member (4) that is attached to and integrated with (3b) and the back surface (2b) of the pad body. The plate-shaped cushion member (5), which is formed of a foam having a lower hardness than the tip member (3) and covers the surface (3a) of the tip member, further includes a bendable plate-like cushion member (5). The rear seat pad of any one of Claims. The side wall surfaces (32 to 34) around the four sides in a plan view of the chip member (3) surrounded by the pad body (2) are roughened to form a rough surface by surface treatment. The rear seat pad described in 1. In the manufacturing method of the rear seat pad (1) of the rear seat for vehicles,
Using the foaming mold (6) that forms the cavity (CA) of the rear seat pad when the mold is closed, first, the seat pad part (W2) that forms the seat in the middle in the vehicle width direction, and the upper surface is substantially flat in the vehicle longitudinal direction The mold surface (7a) according to one split mold (7) corresponding to the raised part (12) that rises upward from the rear end of the flat part (11) for the seat and enters under the back pad (BP), Set the chip member (3) that has been molded to be harder than the hardness of the flat part (11), and set the sheet-like backing member (4) on the mold surface (8a) of the other split mold (8). Then, after injection of the foaming raw material (f) including the back surface (3b) side of the chip member (3), the mold is closed, and then the chip member surface (3a) is exposed to the raised surface (12a), and The pad body (2) in which the chip member (3) is embedded and integrated is foam-molded so that the chip member back surface (3b) is attached to the backing member (4) together with the pad body back surface (2b). Method of manufacturing a rear seat pad characterized.

Images