JP2015137090A - Back pad and rear side material for back pad - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rear side material for a back pad, which can be maintained at low cost using cutting and sewing and further prevent frictional sounds generated around vertical holes regardless of the low cost.SOLUTION: In the rear side material for a back pad of a back rest that is a seat for a vehicle and has at least two vertical stay-insertion holes in a pad main body 2 are provided two cut pieces 4A and 4B, divided at a position to make the vertical holes 20 in the pad main body 2 by cutting a cloth seat material and then cut off into a vehicle front side piece and a vehicle rear side piece, which have protruding pieces 45 expanding from a principal portion 41 of the main body extended respectively at sites corresponding to the vertical holes 20. By sewing together portions 55 to be sewn together including both cut pieces 4A and 4B and also sewing together both side edges of two overlapped protruding pieces 45 and 45, nozzles 52a in the vertical holes 20 are formed by tip edges 46 of the protruding pieces and tubular portions 52 to be abutted on hole walls 201 forming the vertical holes 20 in the pad main body 2 are provided.

Description

  The present invention relates to a vehicle seat and a back pad that constitutes a backrest and a back material for the back pad.

A back pad relating to a vehicle seat such as an automobile may generate an abnormal noise such as a rubbing sound with the movement of an occupant between the back pad and the pipe frame that supports the back pad. In order to prevent this abnormal noise, a cloth back surface material such as a nonwoven fabric is attached to the back surface of the back pad in recent years. The pad body is integrally formed by inserting a back material.
By the way, although a vertical hole for inserting a headrest stay is provided in the upper part of the back pad main body, it is difficult to apply the back material to the hole wall of the pad main body that forms the vertical hole. The back material is a flat sheet material cut and cut and then stitched into a shape along the back surface of the pad body. The conventional back material is simply cut out a hole such as a circular hole in the portion that overlaps the vertical hole. However, they were merely (JP 2005-238675, JP 2006-7418, 2011-143746, etc.). When the headrest is attached to the backrest, the stay holder or the stay holder support frame comes into contact with the hole wall of the pad main body that forms the vertical hole, which causes a problem that rubbing noise is generated by the vehicle running or the movement of the occupant.
Inventions for improving such problems have been proposed (for example, Patent Documents 1 and 2).

JP-A-5-130923 Japanese Patent No. 4541778

However, Patent Documents 1 and 2 have the following problems.
Patent Document 1 states in paragraph 0010 “Furthermore, a through-hole portion 3 leading from the back surface to the surface is formed at the attachment position of the additional member 6 such as a headrest, and a reinforcing layer needs to be formed also in the through-hole portion 3. Invented “a molded reinforcing fabric for cushion material in which a non-woven fabric having moldability is formed into a shape suitable for a foam” according to claim 1, is a high-cost product. When making a relatively simple product without complicated undulations such as a back pad, do not rely on thermoforming of molded reinforcing fabric such as molded felt, but cut and stitch as in JP 2005-238675 It is much cheaper to make a three-dimensional shape.
Patent Document 2 is limited to the technical content of paragraph 0021, “the mounting hole 38 for the headrest is provided in the back cloth 14 at a position corresponding to the mounting hole 22 of the pad body 2”. The mounting hole 38 is only cut out in a U-shape on the back cloth, and even if the tongue piece portion in the U-shape is applied to the hole wall in the mounting hole 22, it remains on only one side wall of the hole wall. Since the remaining three pad bodies are bare hole walls, it is still difficult to prevent rubbing noise.
In particular, rubbing sounds are likely to be noticed because they are emitted near the passenger's ears, and there are increasing cases of concern due to the recent appearance of quiet hybrid vehicles and the like.

  The present invention solves the above-mentioned problem, maintains the cost reduction by using cutting and stitching, and yet applies the back material to all the peripheral wall surfaces of the hole wall, so that the vertical hole is accompanied with the vehicle running and the movement of the occupant. An object of the present invention is to provide a back pad and a back pad material for the back pad that can completely prevent rubbing noise generated around.

In order to achieve the above object, the gist of the invention described in claim 1 is a back seat for a back pad of a backrest having a seat body for a vehicle and having two or more stay insertion vertical holes (20) in a pad body (2). In the material, by cutting the cloth sheet material, the pad body (2) is divided at the place where the vertical hole (20) is formed, and is separated into the vehicle front side and the vehicle rear side, and the vertical hole (20) The projecting part (45) that protrudes from the main part (41) of the main body has two cut pieces (4A, 4B) that extend from the main part (41), and stitches together including both the cut pieces (4A, 4B). By stitching the portion (55) and stitching along both side edges of the two projecting piece portions (45, 45) that are overlapped, the tip edge (46) of the projecting piece portion is inserted into the vertical hole (20). A back pad material for a back pad, characterized in that a cylindrical portion (52) is formed to form a cylindrical opening (52a) and is applied to a hole wall (201) that forms a vertical hole (20) of a pad body (2). is there. According to a second aspect of the present invention, there is provided a back pad back material according to the first aspect, wherein the two cut pieces (4A, 4B) are made of different materials having different properties. According to a third aspect of the present invention, there is provided a back pad back material according to the first or second aspect, wherein the width of the projecting piece portion (45) is set from the base end side connected to the main body main portion (41) to the distal end of the projecting piece portion (45). And the inner diameter (d) of the cylindrical opening (52a) is smaller than the outer diameter (D) at the corresponding position of the vertical hole forming protrusion (631) according to the back pad foaming mold (6). Characterized by being made smaller.
The gist of the invention described in claim 4 is that in the back pad of the vehicle seat having two or more stay insertion vertical holes (20) in the pad main body upper part (22), the vertical holes are formed by cutting the cloth sheet material. (20) is divided at the place where it is to be created, separated into the vehicle front side and the vehicle rear side, and overhangs from the outer peripheral edge (42) of the main body (41) to the part corresponding to the vertical hole (20). The projecting piece portion (45) has two cut pieces (4A, 4B) each extending, and stitches the stitched portion (55) including both the cut pieces (4A, 4B), and two superimposed pieces. By stitching along both side edges of the projecting piece portions (45, 45), a cylindrical opening (52a) in the vertical hole (20) is formed at the front end edge (46) of the projecting piece portion, and the pad body (2 ) And a back material (3) provided with a cylindrical portion (52) applied to a hole wall (201) that creates a vertical hole (20), and the cylindrical portion (52) is attached to the hole wall (201), In addition, the cutting piece (4A) on the front side of the vehicle on the back surface is attached. And a pad body (2) integrally foam-molded by attaching the rear surface (3B) formed by the cut piece (4B) on the rear side of the vehicle to the rear surface (2b). The back pad is characterized by

As in the first and fourth aspects of the invention, when the projecting piece portions (45) projecting from the main body main portion (41) are overlapped and sewn along both side edges, the entire hole wall (201) that forms the vertical hole (20) is formed. The cylindrical portion (52) applied to the cylinder can be easily manufactured, and the rubbing sound generated around the vertical hole as the vehicle travels or the occupant moves can be prevented.
As in the second aspect of the invention, if the two cut pieces (4A, 4B) are made of different materials with different properties, it is possible to individually respond to the required specifications of each part where the back material is arranged, and to reduce the cost. Improve quality while aiming.
As in the invention of claim 3, the width of the projecting piece portion (45) is tapered from the base end side connected to the main body main portion (41) toward the distal end side of the projecting piece portion (45), and the cylindrical port (52a ) Is smaller than the outer diameter (D) at the corresponding position of the vertical hole forming projection (631) of the back pad foaming mold (6), the vertical hole in the back material during foam molding The insertion set of the forming protrusion (631) is facilitated. In addition, if the projecting piece is tapered toward the tip side, the tip can be brought into close contact with the projection for forming the vertical hole (631) at the tip, which suppresses leakage of foaming raw material into the tube during foam molding. Can do.

  Since the back pad and the back material for the back pad of the present invention attach the cylindrical part to all the peripheral wall surfaces of the hole wall forming the vertical hole, and attach and integrate the back material with the cylindrical part by foam molding of the pad body, Not only can it eliminate the rubbing noise that occurs around the vertical holes as the vehicle travels and the movement of the occupant, but it can also be manufactured at low cost because the back material with the cylinder can be made of sewn products without relying on molded felt. Excellent effects such as being able to.

It is one form of the back pad of this invention, and the back material for back pads, and is a top view of the cut piece for back materials. FIG. 2 is a plan view of a back material made by sewing the cut pieces of FIG. 1. It is a fragmentary perspective view which shows a mode just before setting the back surface material of FIG. 2 to a middle type. It is a fragmentary perspective view which shows the state which set the back surface material of FIG. 2 to the middle type. (A) is a cross-sectional view corresponding to FIG. 3, and (b) is a cross-sectional view corresponding to FIG. (A) is an enlarged view around the cylinder part of FIG. 2, and (b) is an explanatory cross-sectional view showing a state in which the cylinder part of (a) is opened in a middle size. (A) is a longitudinal sectional view of the back pad, and (b) is a partially enlarged view of (a). It is explanatory sectional drawing of the mold open state which shows a mode that a back pad is foam-molded. It is explanatory drawing sectional drawing of a mold closed state which shows a mode that a back pad is foam-molded. (A) is a perspective view of a back pad, (B) is an enlarged perspective view around a vertical hole of (A), and (C) is a plan view of (B). FIG. 4 is another embodiment of the back pad rear surface material, in which (a) is a developed plan view of the cut piece, (b) is a plan view of the back material, and (c) is a view taken along line XX of (b). FIG. 4 is a reference view of a back pad rear material, in which (a) is a developed plan view of the cut cloth, and (b) is a perspective view of a main part showing a state in which the back material is set in a middle size.

  Hereinafter, the back pad and the back material for back pad according to the present invention will be described in detail. 1 to 11 show one embodiment of the back pad and the back pad material for the back pad according to the present invention, FIG. 1 is a plan view of a cut piece for the back piece, and FIG. 2 is a back piece made by stitching the cut piece of FIG. FIG. 3 and FIG. 4 are partial perspective views showing how the back material of FIG. 2 is set in the middle mold, FIG. 5 is a cross-sectional view corresponding to FIG. 3, and (b) corresponds to FIG. 6A is an enlarged view around the cylinder portion of FIG. 2, FIG. 6B is an explanatory sectional view of the opening of the cylinder portion of FIG. 7A, and FIG. FIG. 8 and FIG. 9 are explanatory sectional views showing how the back pad is foam-molded, and FIG. 10 is a perspective view of the back pad. (B) is a plan view of (b), and FIG. 11 is an explanatory view of a back material of another embodiment. 5 (b), FIG. 7 (a), and FIG. 10 (c) are drawn slightly apart from the pad body 2 in order to make the back surface material 3 easy to understand.

(1) Back Pad Back Material The back pad back material 3 is a back pad of a vehicle seat having two or more stay insertion vertical holes 20 in the pad main body upper part 22, and is integrally attached to the back surface 2 b of the pad main body 2. This is a sewn back material. The back material 3 is a sewn product cut and stitched from a cloth-like sheet material such as a nonwoven fabric. The back pad back material 3 that is cut and sewn from a flat cloth sheet material is divided into two parts at the location where the vertical hole 20 of the pad body 2 is formed, and is separated into a vehicle front side and a vehicle rear side. 4A and 4B (FIGS. 1 and 7). Projecting pieces 45 projecting from the outer peripheral edge 42 of the main body main portion 41 extend in portions corresponding to the vertical holes 20 in the cutting piece 4A on the vehicle front side and the cutting piece 4B on the vehicle rear side, respectively.

Sewing allowance portions are provided in the stitched portions of the vehicle front side cutting piece 4A and the vehicle rear side cutting piece 4B, respectively. The back pad 3 for the back pad 3 is formed by stitching the stitched portion 55 including both the cut pieces 4A and 4B and stitching along the both side edges of the two overlapping projecting pieces 45 and 45 into a cylindrical shape. While being sewn to the whole shape, the cylinder part 52 is made. A cylindrical opening 52a in the vertical hole 20 is formed at the tip edge 46 of the projecting piece 45, and the back pad back surface material is provided with the cylindrical portion 52 applied to the hole wall 201 forming the vertical hole 20 of the pad body 2 (FIG. 7). ).
As for the cylindrical portion 52, if a forming felt by vacuum forming or the like is employed, there is a limit to the elongation of the material, and the cylindrical portion height T cannot be secured sufficiently in many cases. Since the back material 3 of the present invention is composed of the cut pieces 4A and 4B divided into a plurality of parts, the height Z of the projecting piece 45 can be freely set, so that it can be adapted to the height h20 of the vertical hole 20. The cylindrical portion 52 having a high height can be easily manufactured.

  The protruding piece 45 of the vehicle front side cutting piece 4A and the protruding piece 45 of the vehicle rear side cutting piece 4B have the same shape. Both projecting pieces 45 may have a rectangular shape, but it is more preferable to form a trapezoidal shape as shown in FIG. Specifically, the width of the projecting piece 45 tapers from the base end side connected to the main body main portion 41 toward the distal end side of the projecting piece 45, and the inner diameter d of the tube port 52a associated with the tube portion 52 is set to a back pad to be described later. It is slightly smaller than the outer diameter D at the corresponding position of the vertical hole forming projection 631 of the foaming mold 6 (FIG. 6). This is because the foaming of the pad main body 2 can suppress the leakage of the foaming raw material from the tube opening 52a (details will be described later). Further, by making the protruding piece portion 45 into a trapezoidal shape, the base end portion of the cylindrical portion 52 can be relaxed, and the protruding portion 631 can be easily inserted into the cylindrical portion 52 when the back pad body is molded.

The present embodiment is applied to a driver's seat back pad having two vertical holes 20. By sewing the vehicle front side cutting piece 4A and the vehicle rear side cutting piece 4B as shown in FIG. 1, a back pad back surface material 3 as shown in FIGS. As shown in FIG. 1 (a), the vehicle front side cut piece 4A protrudes from the upper edge 42 to the left and right outwards from a substantially rectangular main part 41a having a projecting piece 45 and a side edge 43 of the main part. And a sleeve portion 41b. In the present invention, “upper edge” and “upper” are back pads in a state assembled to a vehicle, and refer to the upper edges and upper parts of the pad main body, the back surface material, and the cut pieces.
The sleeve portion 41b is a trapezoid as shown in the figure which protrudes from the upper end of the main portion 41a to the outside and then protrudes laterally outward from the main portion 41a with a certain width to a point past the lower half of the main portion 41a. It has a shape. The vehicle rear side cutting piece 4B is a horizontally elongated substantially inverted trapezoidal cutting piece having a protruding piece portion 45 protruding from the upper edge 42 as shown in FIG. The lateral length of the upper side of the vehicle rear side cut piece 4B corresponding to the lower base of the substantially inverted trapezoidal shape is substantially equal to the length of the upper side of the main portion 41a related to the vehicle front side cut piece 4A. Corresponds to. Reference numeral 441 denotes a notch provided in the upper base of the substantially trapezoidal shape. This is because it is easy to form the three-dimensional shape of the back material 3. Reference numeral 431b indicates a bending point provided on the right sleeve 41b.

In the vehicle front side cutting piece 4A, in FIG. 10, the main portion 41a covers the back surface 2b of the pad main body 21 on the front side of the vehicle with respect to the vertical hole 20 in the pad main body upper portion 22, and the sleeve portion 41b is in front of the vehicle. The back side 2b of the side rear part 24 is covered by turning to the back side of the main part so as to surround the pipe frame from the side of the pad main part 21 on the side. The vehicle rear side cutting piece 4 </ b> B covers the back surface 2 b of the pad main body rear portion 23 on the vehicle rear side with respect to the vertical hole 20 in the pad main body upper portion 22.
The two cutting pieces 4A and 4B have a separate structure initially separated into a vehicle front side and a vehicle rear side. Therefore, the same material may be used, but it can be made of different materials having different properties by changing the basis weight or changing the kind of nonwoven fabric or the lamination specification according to the required specifications of each part. For example, in the foam molding of the pad main body 2, the back material 3 tends to be easily impregnated by the vehicle front side main portion 21 from the mold structure of FIG. 9. While the vehicle rear side cutting piece 4B has a two-layer structure, a three-layered nonwoven fabric such as Tafnel (registered trademark) manufactured by Mitsui Chemicals, Inc. is used for the vehicle front side cutting piece 4A to eliminate such impregnation defects. It is also possible to use a cut piece 4 using a durable Toyobo Bolance (registered trademark) or the like on the back surface 2b side of the pad main body upper portion 22 where the pipe frame hits.
In the present embodiment, the back material 3 is formed by the vehicle front side cutting piece 4A and the vehicle rear side cutting piece 4B divided into two parts, but the vehicle front side cutting piece 4A can be further divided as necessary. When the sleeves 41b are separated and the back material 3 is formed by the four divided pieces 4, the stitched portions 55 of the four pieces are stitched together, and the two protruding pieces 45, 45 are overlapped. By stitching along both side edges, the back pad back material 3 is sewn.

Next, an example of sewing the back pad backside material 3 with the vehicle front side cutting piece 4A and the vehicle rear side cutting piece 4B will be described. First, the vehicle front side cutting piece 4A in FIG. 1 (a) and the vehicle rear side cutting piece 4B in FIG. 1 (b) are overlapped so that the protruding pieces 45 and the upper edge 42 coincide with each other. The stitched portion 55a along the edge 42 is sewn. Before and after this, both side edges of the overlapping projecting piece 45 are stitched together to form a stitching line 51 to be a cylindrical portion 52. Further, at the boundary line 49 between the main portion 41a and the sleeve portion 41b, the sleeve portion 41b is bent toward the side where the vehicle rear side cutting piece 4B is present. Then, the folded back sleeve portion 41b and the vehicle rear side cut piece 4B are aligned as shown in FIG. In the stitched portion 55 of the sleeve portion 41b and the vehicle rear side cutting piece 4B, the right side portion 55c stops sewing from the corner portion 48 to the middle bending point 431b so that the back material 3 can be formed into a three-dimensional shape, while the left side portion 55b. Since the notch 441 is provided, the back pad back surface material 3 is sewn from the corner 48 to the inner end. Thus, a desired three-dimensional shape can be formed as shown in FIGS. 2 to 7, and a desired back material 3 that can be attached to the pad main body back surface 2b is completed. In the figure, reference symbol DB denotes a double portion between the vehicle rear side cut piece 4B and the sleeve portion 41b, reference symbol 51N denotes a seam of the tubular portion forming suture line 51, and reference symbols 4A ₉ and 4B ₉ denote stitch margins. Reference numeral 55N indicates a seam for sewing the stitched portion 55.

FIG. 11 shows a schematic view of the back pad back material 3 according to another embodiment. FIG. 11 (a) is a plan view of the cut pieces 4A and 4B of the back material 3, (b) is a plan view of the back material 3 formed by stitching both the cut pieces 4A and 4B of (b), and (c) is ( (B) is a view taken along line XX. The back pad 1 of the rear seat of the vehicle is provided with three cylindrical portions 52 that are applied to the hole wall 201 of the vertical hole 20 as the back material 3 attached to the back surface 2b of the pad main body 2.
Other configurations are the same as those of the back material 3 of FIGS. 1 to 10 indicate the same or corresponding parts.

(2) Back pad The back pad 1 is a back pad of a vehicle seat having two or more stay insertion vertical holes 20 in the pad main body upper part 22. The back pad 1 is formed by attaching the back surface material 3 shown in FIGS. 2 to 7 and the cylindrical portion 52 of the back surface material 3 to the hole wall 201 and forming the front surface portions 3A, 4B, 4B. And a pad main body 2 that is integrally foam-molded by attaching the rear surface portion 3B to the back surface 2b.

  The back material 3 is the aforementioned sewing product. At the site corresponding to the vertical hole 20, the stitched portions 55 of the two cut pieces 4A and 4B each extending from the projecting piece portion 45 extending from the main body portion 41 are sewn together, and the two projected piece portions 45, It is the back material 3 in which the cylinder part 52 was provided by sewing along the both side edges of 45.

  The pad main body 2 is a foam molded product formed in the shape of the backrest portion of the driver's seat back pad 1 using a foamed resin material such as a polyurethane material (FIGS. 7 and 10). As shown in FIG. 7, the pad main body 2 extends from the front main portion 21 serving as the backrest portion of the occupant to the upper portion 22 where the headrest 8 is mounted, and then bends downward to form a recess u. The rear side rear part 23 hangs down. As for the side edge part of the front side main part 21, the upper half part protrudes in the vehicle rear as shown in FIG. The lateral rear portion 24 is connected to the rear portion 23 to form a recess u. A vehicle body side pipe frame is mounted in the recess u to stably support the pad main body 2.

A vertical hole 20 for stay mounting is formed in the upper portion 22 of the pad main body 2 in the vertical direction by foam molding. In the foam molding, the inserted back material 3 adheres to the pad main body back surface 2b, but the tip edge 46 of the projecting piece 45 forms the upper side cylinder port 52a of the cylinder 52, and the cylinder 52 is a vertical hole. 20 is attached to the hole wall 201, and the pad body 2 is integrally foamed with the back material 3 (FIG. 7). The cylindrical portion 52 of the back material 3 is attached to the hole wall 201, and the front surface portion 3A formed by the cut piece 4A on the vehicle front side of the back material 3 and the rear surface portion 3B formed by the cut piece 4B on the vehicle rear side are formed on the back surface 2b. The pad main body 2 is integrally formed by foaming.
Here, the vertical hole 20 is a square hole as shown in FIG. 10, and in accordance with this, the cylindrical portion 52 of the back material 3 is also a square cylinder. As shown in FIG. 10 (c), the cylindrical projecting piece 45 of the vehicle front side cutting piece 4A located on the upper side of the figure is bent into a U-shape and the cylinder of the vehicle rear side cutting piece 4B located on the lower side of the figure. By bending the protruding portion 45 for the portion into a U-shape, the protruding piece of the vehicle front side cutting piece 4A (specifically, the main portion 41a) attached to the back surface 2b of the pad main body upper portion 22 as shown in FIG. part inner portion 4A _1, on the protruding portions closer portion 4B ₁ of the vehicle rear-side trimming strips 4B, it can be erected tubular portion 52.

  Since the cylindrical part 52 is literally finished into a cylindrical body, it covers the hole wall 201 related to the pad body 2 that forms the vertical hole 20 as shown in FIGS. The cylindrical projecting piece 45 having a height Z corresponding to the vertical hole height h20 can be easily manufactured by cutting, and the cylindrical portion 52 is applied to substantially the entire area of the hole wall 201 in the height direction of the vertical hole 20. .

  Here, before reaching the present invention, the inventor invented the improved back surface material RN of FIG. 12 (b) formed by sewing the cut cloth shown in FIG. 12 (b). The outer peripheral edge of the cut cloth CL provided with the H-shaped slit SL at a position corresponding to the vertical hole 20 was stitched to obtain an improved back surface material RN. 8 and 9, the cut cloth CL is set in the middle die 63 so that the protruding portion 631 is passed through the H-shaped slit SL, and the pad main body 2 is foam-molded. Countermeasures were insufficient. When the back surface material RN of FIG. 12 (b) is adhered and integrated to the pad main body back surface 2b, the two tongue pieces TH surrounded by the slits SL are formed on the two wall surfaces having hole walls in all directions. I stayed in contact. Compared to the one that has a hole on one side of the wall as in Patent Document 2, the countermeasure against abnormal noise is improved, but the remaining two walls expose the pad body itself. The abnormal noise generation could not be suppressed.

  On the other hand, the back material 3 of the present invention covers the vertical holes 20 of the pad main body 2 by applying the cylindrical portion 52 to all four wall surfaces of the quadrangular columnar hole wall 201 (FIG. 10). In the vertical hole 20, there is no portion where the pad body 2 is exposed except in the vicinity of the upper opening 200 of the vertical hole 20. In the present embodiment, as shown in FIG. 7, the upper opening edge 521 of the cylindrical portion 52 is slightly retracted into the vertical hole 20 rather than the upper opening 200 of the vertical hole 20, but the exposure of the pad main body 2 is very slight. There is no problem at all. Further, the actual pad main body 2 has an opening at the opening of the vertical hole 20 extending from the upper opening edge 521 of the cylindrical portion 52 toward the upper opening 200 of the vertical hole 20. The HL and the stay holder support frame do not come into direct contact with the pad main body 2, and countermeasures against abnormal noise are perfect. Reference numeral 25 indicates a raised portion for a vertical hole formed on the pad main body upper portion 22.

Next, a method for manufacturing the back pad 1 will be described.
Prior to the manufacture of the back pad 1, the back surface material 3 with the cylindrical portion 52 as shown in FIGS. 2 and 3 is prepared. The foaming mold 6 used for manufacturing the back pad 1 is a foaming mold as shown in FIGS. 8 and 9, and includes a lower mold 61, an upper mold 62, and a middle mold 63. When the mold is closed as shown in FIGS. 8 to 9 with the hinge 69 as a fulcrum, the mold surface 610 of the lower mold 61, the mold surface 630 of the middle mold 63, and the mold surface 620 of the upper mold 62 having a large degree of depression as a whole. Thus, the cavity C of the back pad 1 in which the back material 3 is integrated with the pad main body 2 is formed. In this manufacturing method, the surface 2 a side of the back pad 1 is formed by the mold surface 610 of the lower mold 61 and the mold surface 620 of the upper mold 62, and the back surface 2 b side of the back pad 1 is molded by the mold surface 630 of the middle mold 63.

The back pad 1 is manufactured using the foaming mold 6 and the back material 3 as follows, for example. First, the foaming mold 6 is opened (FIG. 8). Next, the back material 3 is set on the middle mold 63 under this mold open state.
The middle die 63 is provided with a shaft-like protruding portion 631 in the shape of the vertical hole 20 so as to protrude from the main portion. When wearing the setter, the projecting portion 631 is passed through the cylindrical portion 52 as shown in FIG. 5 (a) so that the hand is passed through the arm portion of the theta, and the back material 3 is attached to the middle die 63 as shown in FIG. 5 (b). Set. The protruding portion 631 has a quadrangular prism shape, and a root portion of the protruding portion 631 expands along the cylindrical portion 52. Under the mold open state of FIG. 8, the state of FIG. 3 is changed to the state of FIG. 4, and the back material 3 is set on the middle mold 63. Even in the case of the sewing tube portion 52, the width of the projecting piece portion 45 is tapered from the base end side connected to the main body main portion 41 toward the distal end side of the projecting piece portion 45, and the tube portion 52 is directed toward the root portion. Since it becomes a cylinder opening which spreads in the shape of an eight, the protrusion 631 enters the large opening on the root part side without difficulty. The cylindrical portion 52 has a rectangular cylindrical shape that covers and surrounds the protruding portion 631. As shown in the enlarged view in the circle of FIG. 4, the protruding portion 631 slightly protrudes from the upper opening edge 521 of the cylindrical portion 52.
Although not shown in the drawings, a ferrite tape piece is attached to an appropriate portion of the back surface material 3 and a permanent magnet is exposed on the mold surface 630 of the middle mold 63 corresponding to the tape piece. The back material 3 is securely set on the mold surface 630 of the middle mold 63.

  Next, a predetermined amount of foaming raw material g is injected while the mold is open (FIG. 8), and then the mold is closed. By closing the upper mold 62, the lower mold 61, and the middle mold 63, the cavity C of the back pad 1 into which the back material 3 is inserted is formed (FIG. 9). At the same time, the tip of the protruding portion 631 comes into contact with the raised portion 611 of the lower mold 61 to prepare for forming the vertical hole 20. In the figure, reference numerals 619, 629, and 639 denote mold matching surfaces, reference numeral 67 denotes a support bar, reference numeral 68 denotes an arm, and reference numeral 68a denotes a hook.

After closing the mold, the process proceeds to foam molding of the pad body 2. The mold closed state is maintained for a predetermined time, and the pad main body 2 as shown in FIGS. 7 and 10 is foam-molded so that the back surface material 3 is adhered and integrated on the back surface 2b side. Since the inner diameter d of the cylindrical port 52a is slightly smaller than the outer diameter D of the protruding portion 631, the foaming raw material g does not leak into the cylindrical portion 52 during foam molding. Thus, the back pad 1 in which the pad main body 2 and the back surface material 3 are integrated is manufactured. Since the cylindrical portion 52 surrounds the quadrangular columnar protruding portion 631 and the back material 3 is set on the middle die 63, a cylindrical shape is formed on all wall surfaces that circulate the pad body hole wall 201 that forms the vertical hole 20. A desired back pad 1 in which the cylindrical portion 52 is integrally bonded is completed.
When the back pad 1 is covered with an unillustrated skin, it becomes a backrest for the backrest of the vehicle seat.

(3) Effect The back pad and the back pad back material 3 configured in this way are manufactured by sewing the cut pieces 4 without relying on the thermoforming of a molding reinforcing cloth such as a molding felt as in Patent Document 1. In particular, the back pad 1 having a relatively simple three-dimensional shape can be produced at low cost and is extremely useful.

Moreover, even if it says the sewing back material 3, unlike the back material 3 of patent document 2, the cylinder part 52 of the back material 3 covers and forms the cylinder part around the hole wall 201 which concerns on the vertical hole 20 360 degree | times. 52 is attached to the hole wall 201, and the back pad 1 in which the back surface material 3 is integrated with the pad main body 2 is completed, so that the generation of abnormal noise can be reliably suppressed.
The tongue piece part cut out in the U-shape of Patent Document 2 is applied to only one wall surface of the four sides of the hole wall, or only two wall surfaces of the four sides of the hole wall as shown in FIG. Unlike the case where it does not, the back material 3 applies all the peripheral wall surfaces of the four sides of the hole wall 201 with the cylindrical portion 52 and covers them, so that the measure against abnormal noise becomes a meteorite. The rubbing sound generated around the vertical hole 20 as the vehicle travels and the passenger moves can be prevented.

Furthermore, the back material 3 for the back pad of the molded felt made by vacuum forming or the like has a limit in the elongation of the material, and it is difficult to form the cylindrical portion 52 having a necessary height applied to the hole wall 201 of the vertical hole 20. However, since the back surface material 3 bears the protruding piece 45 of the cut piece, the cylindrical portion 52 having a required height can be obtained without difficulty. Suppression of rubbing sound is perfect.
In addition, since the back material 3 is a sewn product using a plurality of cut pieces, it is easy to obtain a composite back material 3 of different kinds of cut pieces adapted to the required quality of each part, and further quality improvement and low cost. Demonstrates excellent effects for the purpose of commercialization.

  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 back pad 1, the pad body 2, the vertical hole 20, the back surface material 3, and the cutting cloth 4 can be appropriately selected according to the application.

2 Pad body 20 Vertical hole 201 Hole wall 4A, 4B Cutting piece 41 Main body main part 45 Projection part 52 Tube part 52a Tube opening 55 Sewing part 6 Foaming type 631 Projection part d Inner diameter (inner diameter)
D Outer diameter of protrusion (outer diameter)

Claims (4)

In the back seat material for the backrest of the backrest having two or more stay insertion vertical holes (20) in the pad body (2) in the vehicle seat seat,
By cutting the cloth sheet material, the pad body (2) is divided at the place where the vertical hole (20) is created, and is separated into the vehicle front side and the vehicle rear side, and corresponds to the vertical hole (20). The projecting piece portion (45) projecting from the main body main portion (41) is provided with two cut pieces (4A, 4B) respectively extending in the part,
By stitching the stitched portion (55) including both the cut pieces (4A, 4B) and stitching along both side edges of the two superimposed projecting piece portions (45, 45), A cylindrical portion (52) is formed by forming a cylindrical opening (52a) in the vertical hole (20) at the tip edge (46) and forming a vertical wall (201) of the pad body (2). The back material for back pads characterized by the above. The back material for a back pad according to claim 1, wherein the two cut pieces (4A, 4B) are made of different materials having different properties. The width of the projecting piece portion (45) is tapered from the base end side connected to the main body main portion (41) toward the distal end side of the projecting piece portion (45), and the inner diameter (d) of the cylindrical port (52a) is reduced. The back pad back surface material according to claim 1, wherein the back pad back surface material is smaller than an outer diameter (D) at a corresponding position of the vertical hole forming protrusion (631) of the back pad foaming mold (6). In the back pad of the vehicle seat with two or more stay insertion vertical holes (20) in the pad main body upper part (22),
By cutting the cloth sheet material, the vertical hole (20) is divided at the place where the vertical hole (20) is formed, and is separated into the vehicle front side and the vehicle rear side, and the main part of the main body (at the site corresponding to the vertical hole (20) ( 41) has two cutting pieces (4A, 4B) extending from the outer peripheral edge (42) of the outer peripheral edge (42), respectively, and includes a sewing portion (55) including both cutting pieces (4A, 4B). ) And stitching along both side edges of the two protruding pieces (45, 45) overlapped, so that the tip end edge (46) of the protruding piece portion has a cylindrical mouth (20) in the vertical hole (20). 52a), a back material (3) provided with a cylindrical portion (52) applied to the hole wall (201) that forms the vertical hole (20) of the pad body (2),
The cylindrical portion (52) is attached to the hole wall (201) and the front portion (3A) formed by the cut piece (4A) on the vehicle front side of the back material and the cut piece (4B) on the vehicle rear side And a pad body (2) that is integrally foam-molded by attaching a rear surface portion (3B) formed by the above-mentioned structure to the back surface (2b).

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