JP2017202076A - Cushion pad for vehicle and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion pad for vehicles integrating a polyurethane foam molding pad with a non-breathable foam molding pad to be superposed thereon by mechanical-structurally connecting both in such a manner as to prevent peeling of the polyurethane foam molding pad without increasing workload or elongating a molding cycle, and a manufacturing method thereof.SOLUTION: The cushion pad for vehicles comprises: a core material pad 1 that includes, at a lower face 2b of a block-like molding pad 2, a horizontal groove 37 having one-end-side groove port exposed to one lateral face 2c of a molding pad 2, and a traverse groove 38 disposed into a cross shape, T shape, or L shape with respect to the horizontal groove 37, and in which the horizontal groove 37, the traverse groove 38, and a molding pad 2 are integrally formed as a non-breathable foam molding body; and a surface-layer molding pad 4 that includes a polyurethane foam molding part buried in the horizontal groove 37 and the traverse groove 38, and a polyurethane foam molding part superposed on an upper face 1a and a lateral face 1c of the core pad 1.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a vehicle cushion pad constituting a seat portion of a vehicle seat and a method for manufacturing the same.

  An appropriate cushioning property is required for a cushion pad constituting a seat portion of a seat seat mounted on a vehicle such as an automobile. For this reason, polyurethane foam has been used exclusively, but in recent years there has been a movement to meet the weight reduction of vehicles. Inventions using a non-vented foam of polystyrene foam or polyethylene foam have been proposed for a part of the cushion pad (for example, Patent Documents 1 and 2).

JP-A-9-70330 JP 2010-259535 A

However, Patent Document 1 is claimed in claim 1, “It is a layered different hardness pad of a vehicle seat made of two upper and lower foam layers, the upper layer is made of polyurethane foam, and the lower layer is made of polystyrene foam. It is formed of a body, and the upper and lower layers are integrally bonded to each other, and the layered different hardness pad of the vehicle seat is characterized by the fact that the bonding force between the upper and lower layers is weak. In the detailed description, “... after forming the lower layer 3, the upper layer 2 is foam-molded thereon, and in the molding process of the upper layer 2, a part of the polyurethane stock solution is impregnated on the polystyrene foam side of the lower layer 3, The upper and lower layers 2 and 3 are firmly and integrally joined by the impregnated portion 4. ”However, the joint between the two is not so strong.
Patent Document 2 proposes a “cushion body for a vehicle seat characterized in that a non-vented foam of a polyethylene foam is subjected to an easy adhesion treatment”. According to the detailed description, “the polyethylene foams 12 and 13 are each of which the surface is previously sanded and the surface foamed cell film is broken and roughened”. is there. However, a new work for roughening occurs, and when the surface is roughened, the hardened surface layer is taken, the internal foam layer is exposed, and gas may escape. Moreover, there is a possibility that the surface hardened layer disappears and it becomes brittle.

  The present invention solves the above-mentioned problems, and does not increase the work load and does not lengthen the molding cycle, so that the polyurethane foam molding pad laminated on the molding pad of the non-vented foam is not peeled off. It is an object of the present invention to provide a vehicle cushion pad and a method of manufacturing the same, which are integrated with each other to integrate them.

In order to achieve the above object, the gist of the invention described in claim 1 is that a horizontal groove in which a groove opening on one end side is exposed on one side surface of the molding pad on the lower surface of the block-shaped molding pad, , T-shaped, or L-shaped transverse grooves, and the horizontal groove, the transverse groove, and the molding pad are integrally formed as a non-breathable foamed molded body. A pad, and a polyurethane foam molded part embedded in the horizontal groove and the transverse groove, and a surface layer molded pad provided with a polyurethane foam molded part laminated on the upper surface and the side surface of the core pad. Located on the vehicle cushion pad. A vehicle cushion pad according to a second aspect of the present invention is the vehicle cushion pad according to the first aspect, wherein a vertical groove integrally formed as a part of the molded body related to the core material pad is provided in a vertical direction on a side surface near the lower end of the molding pad. And it is connected with the said horizontal groove in the lower end of this vertical groove, and this vertical groove is further filled with the polyurethane foaming molding part, It is characterized by the above-mentioned. A vehicle cushion pad according to a third aspect of the present invention is the vehicle cushion pad according to the second aspect, wherein the non-breathable foamed molded body is a molded body of foamed polypropylene or foamed polystyrene, and the upper end of the vertical groove reaches the upper surface side of the molding pad. It is characterized by being. A vehicle cushion pad according to a fourth aspect of the present invention is the vehicle cushion pad according to the second or third aspect, wherein a plurality of the vertical grooves are provided apart from each other on one side surface of the molding pad, and a horizontal lateral groove connecting adjacent vertical grooves is provided. It is integrally formed as a part of the molded body related to the core pad, and the horizontal groove is filled with a polyurethane foam molded portion together with the vertical groove.
The gist of the invention described in claim 5 is that the bottom surface of the block-shaped molding pad has a horizontal groove in which a groove opening on one end side is exposed on one side surface of the molding pad, and a cross shape, T-letter shape, or A core pad in which a transverse groove arranged in an L-shape is provided, and the horizontal groove, the transverse groove, and the molding pad are integrally formed as a non-breathable foamed molded article is formed as one foam type. Polyurethane foam molding part that is set on the split mold, and then filled with the polyurethane foam raw material and the mold is closed to fill the horizontal groove and the transverse groove, and the polyurethane foam molding is laminated on the upper surface and the side surface of the core pad And a cushion pad for a vehicle, wherein the surface layer molding pad is foam-molded. According to a sixth aspect of the present invention, there is provided a vehicle cushion pad manufacturing method according to the fifth aspect, wherein a longitudinal groove integrally formed as a part of a molded body related to the core pad is formed in a vertical direction on a side surface near the lower end of the molding pad. And a core material pad connected to the horizontal groove at the lower end of the vertical groove, and after the core material pad is set in one divided mold of the foam type, the vertical groove is formed together with the horizontal groove and the transverse groove. The surface layer molding pad having a polyurethane foam molding part to be filled is foam-molded. According to a seventh aspect of the present invention, there is provided a vehicle cushion pad manufacturing method according to the sixth aspect, wherein the non-breathable foam molded body is a foamed polypropylene or foamed polystyrene molded body, and the upper end of the vertical groove is on the upper surface side of the molding pad. The core material pad reaching the diameter is set in one divided mold of a foam type. A method for manufacturing a vehicle cushion pad according to an eighth aspect of the present invention is the method for manufacturing a vehicle cushion pad according to the sixth or seventh aspect, wherein a plurality of the vertical grooves are provided apart from each other on one side surface of the molding pad and the horizontal direction connects adjacent vertical grooves. These surface grooves are integrally formed as a part of the molded body related to the core pad, and the surface layer forming pad provided with a polyurethane foam molding portion that fills the transverse grooves together with the longitudinal grooves is formed by foam molding.

  The cushion pad for a vehicle according to the present invention and the manufacturing method thereof are foam molding of a surface layer molding pad, and a polyurethane foam molded portion is foam molded together to form a non-breathable foam molded body, and has a concave groove for mechanical coupling. Since the concave grooves related to the core material pad are filled and integrated with each other, the core material pad and the surface layer forming pad are not easily separated, and an excellent effect of integration is exhibited.

1 is an overall perspective view of a cushion pad partially broken in a form of a cushion pad and a manufacturing method thereof according to the present invention. It is the elements on larger scale which looked at the cushion pad of FIG. 1 from the lower surface side. It is sectional drawing of the vertical groove which exists in the front of FIG. It is sectional drawing of the vertical groove in the back of FIG. It is a partial expansion perspective view of the cushion pad of another aspect which replaces FIG. FIG. 6 is a view taken along line VI-VI in FIG. 5. (A) is a longitudinal cross-sectional view of the ditch | groove of the other aspect which replaces FIG. 3 (a), (b) is a top view of (a). It is explanatory sectional drawing which sets the core material pad represented by the VIII-VIII arrow line view of FIG. 5 to the foaming mold in the mold open state used for this manufacturing method, and injects a foaming raw material. FIG. 9 is an explanatory sectional view in which the mold is closed after the foaming raw material is injected in FIG. 8. It is explanatory sectional drawing which foam-molded the cushion pad.

Hereinafter, a vehicle cushion pad (hereinafter also simply referred to as “cushion pad”) and a method for manufacturing the same according to the present invention will be described in detail. 1 to 10 show one embodiment of the cushion pad and the manufacturing method thereof according to the present invention. FIG. 1 is an overall perspective view of the cushion pad partially broken, and FIG. 2 is a view of the cushion pad of FIG. FIG. 3 is a sectional view of a longitudinal groove in front of FIG. 1, FIG. 4 is a sectional view of a longitudinal groove in the back of FIG. 1, and FIG. 5 is a cushion pad according to another embodiment instead of FIG. 6 is a partially enlarged perspective view, FIG. 6 is a view taken along the line VI-VI in FIG. 5, FIG. 7 is a longitudinal sectional view of a concave groove of another embodiment in which (a) replaces FIG. 3 (a), and (b) is (b). FIG. 8 is an explanatory cross-sectional view in which the core pad is set in the foaming mold in the mold open state used in the manufacturing method and the foaming raw material is injected, and FIG. 9 is an explanatory view in which the mold is closed after the foaming raw material is injected in FIG. Sectional drawing and FIG. 10 show explanatory sectional drawing which foam-molded the cushion pad.
In each figure, the main part is highlighted for easy understanding, and parts not directly related to the present invention are omitted.

(1) Cushion Pad for Vehicle The cushion pad P includes a core material pad 1 and a surface layer forming pad 4. This embodiment is applied to a three-seat cushion pad that constitutes a seat portion of a vehicle rear seat as shown in FIG. Like the cushion pad P of FIGS. 1-4, it is the cushion pad which covers and laminate | stacks the upper surface 1a and the side surface 1c of the core material pad 1 with the surface layer forming pad 4 of a polyurethane foam molding part. In the present invention, the “upper surface” and the “lower surface” refer to the “upper surface” on the paper surface and the “lower surface” hidden on the paper surface in the cushion pad P in FIG. . In FIG. 1, the diagonally left side slightly downward toward the paper surface is the front of the vehicle. The cushion pad P in FIGS. 2 to 7 is drawn upside down in order to make the main part of the invention easy to understand.

The core pad 1 is a non-breathable foamed molded body, which is a base body in which a concave groove 3 is integrally formed with a block-shaped molding pad 2 (FIGS. 1 and 2).
The molding pad 2 is a main part of a lump-like non-breathable foamed molded body that is formed by making the cushion pad P of the rear seat into a block shape and making it almost one size smaller. The apparent density of the non-breathable foamed molded product is smaller than that of the surface layer molding pad 4. Here, the non-breathable foamed molded product is a molded product of foamed polypropylene or foamed polystyrene, the apparent density is particularly small, and it is very light for its size. For example, when the foamed polypropylene or expanded polystyrene is formed into a molded body of bead method expanded polypropylene or bead method expanded polystyrene, the inside can be a highly expanded layer with an arbitrary magnification, and the surface can be a cured film layer. A non-breathable foamed article with a surface coating is obtained. In the vehicle installation state shown in FIG. 1, the side surface 2c of the molding pad 2 is a substantially vertical surface, and the lower surface 2b around the lower end of the vertical surface forms a horizontal surface.

  The horizontal groove 37 and the transverse groove 38 of the concave groove 3 are simultaneously formed by forming the molding pad 2. On the lower surface 2 b of the molding pad 2, a groove on one end side is disposed in a horizontal groove 37 exposed on one side surface 2 c of the molding pad 2, and a cross shape, a T letter shape, or an L letter shape with respect to the horizontal groove 37. A transverse groove 38 is provided. The horizontal groove 37, the transverse groove 38, and the molding pad 2 are integrally formed as a non-breathable foamed molded body. The groove line of the horizontal groove 37 is arranged substantially perpendicular to the one side surface 2c so that the other end of the horizontal groove 37 is far from the one side surface 2c of the molding pad 2 (FIG. 2).

In the present embodiment, a longitudinal groove 36 is added to the concave groove 3 as a part of the molded body related to the core material pad 1 of the non-breathable foam molded body, and is integrally formed as a molded body of the core material pad 1. The vertical groove 36 is provided on the side surface 2 c closer to the lower end 21 of the molding pad 2. The vertical groove 36 is formed on the molding pad side surface 2c, and the horizontal groove 37 and the transverse groove 38 are formed on the molding pad 2 in a concave shape in cross section at the molding pad lower surface 2b.
The vertical groove 36 is provided on the side surface 2c of the molding pad 2 in the vertical direction near the lower end 21 thereof. The vertical groove 36 extends toward the molding pad lower surface 2 b and is connected to the horizontal groove 37 at the lower end 361 of the vertical groove 36. This is a bent groove that proceeds from the longitudinal groove 36 provided on the molding pad side surface 2c to the molding pad lower surface 2b side through the longitudinal groove lower end 361. Here, the horizontal groove 37 is a line-shaped groove that is recessed in a cross-sectional shape on the lower surface 2b of the molding pad 2. However, the horizontal length only needs to exist to some extent, and the actual horizontal length is short as shown in FIG.

  The transverse groove 38 is arranged in a cross shape or a T-shape with respect to the horizontal groove 37 on the lower surface 2 b of the molding pad 2. In the present embodiment, a transverse groove 38 intersecting in a T-shape is formed at the tip of a horizontal groove 37 that extends from the lower end 21 on the side surface of the molding pad 2 toward the center on the lower surface 2b side. The groove bottom 38e of the transverse groove 38 may be the same depth as the groove bottom 37e of the horizontal groove 37, but it is more preferable to set it deeper than the groove bottom 37e of the horizontal groove 37 as shown in FIG. This is because if the transverse groove 38 is deepened, the transverse groove filling portion 48 (detailed later) related to the surface layer forming pad 4 covering the core material pad 1 is deeply buried, and the bonding force between the core material pad 1 and the surface layer forming pad 4 is increased. .

  7 shows another embodiment of the recessed groove 3 in place of the recessed groove 3 of FIGS. 1 to 4. On the lower surface 2 b of the molding pad 2, a transverse groove 38 is arranged in a cross shape with respect to the horizontal groove 37. ing. 1, that is, the concave groove 3 in FIG. 4, extends from the lower end 361 of the vertical groove 36 to the point of the transverse groove 38 on the side of the core pad lower surface 1 b from the horizontal groove 37. However, the horizontal groove 37 in FIG. 7 has a protruding groove 37A that crosses the transverse groove 38 and further toward the center of the lower surface.

The surface layer molding pad 4 is a cushion provided with a polyurethane foam molding part laminated on the upper surface 1a and the side surface 1c of the core pad, together with a polyurethane foam molding part embedded in the vertical groove 36, the horizontal groove 37, and the transverse groove 38. It is a surface layer side pad of the pad P. As described above, the vertical groove 36, the horizontal groove 37, and the transverse groove 38 are formed on the upper surface 1 a and the side surface 1 c of the core material pad together with the molding pad 2 related to the core material pad 1. A surface layer molding pad 4 in which a polyurethane foam molding part buried in the vertical groove 36, horizontal groove 37, and transverse groove 38 and a polyurethane foam molding part laminated on the upper surface 1a and the side surface 1c of the core pad are integrated. Cover the core pad 1. On the upper surface 1a and side surface 1c of the core pad, the upper surface layer portion 41 and the side surface layer portion 42 of the polyurethane foam molded portion related to the surface layer forming pad 4 forming the outer shape of the cushion pad P are laminated. In the longitudinal groove 36, the horizontal groove 37, and the transverse groove 38, a longitudinal groove filling portion 46, a horizontal groove filling portion 47, and a transverse groove filling portion 48 of a polyurethane foam molding portion related to the surface layer molding pad 4 are formed in each groove shape. Filled with mating form.
Also in the horizontal groove 37 having the protruding groove 37A in FIG. 7, the horizontal groove filling part 47 of the polyurethane foam molded portion is buried in the horizontal groove 37 including the protruding groove 37A and laminated on the upper surface 1a and the side surface 1c of the core pad. The upper surface layer portion 41 and the side surface layer portion 42 become the surface layer molding pad 4.

5 and 6 show another type of cushion pad P in place of the cushion pad P shown in FIGS. 1 to 4, and further shows a cushion pad provided with a lateral groove 39. The lateral groove 39 is also a part of the molded body related to the core pad 1 of the non-breathable foam. A plurality of longitudinal grooves 36 are provided on one side surface 2c of the molding pad 2 so as to be spaced apart from each other, and a horizontal lateral groove 39 that connects the adjacent longitudinal grooves 36 is provided. Further, together with the longitudinal grooves 36, the lateral grooves 39 are also made of polyurethane foam. Filled with molding part. The cushion pad P in FIG. 5 is provided with two longitudinal grooves 36, and three transverse grooves 39 connecting the longitudinal grooves 36 are provided apart from each other, and these are the longitudinal groove filling part 46 and transverse groove filling of the polyurethane foam molded part. Filled with part 49.
As described above, the longitudinal groove 36, the horizontal groove 37, the transverse groove 38, and the transverse groove 39 are formed on the upper surface 1a and the side surface 1c of the core pad shown in FIG. The upper surface layer portion 41 and the side surface layer portion 42 of the polyurethane foam molded portion that forms the outer shape of the cushion pad P are laminated on the upper surface 1a and the side surface 1c of the core pad. The surface layer molding pad 4 is foam-molded so that 36, the horizontal groove 37, the transverse groove 38, and the lateral groove 39 are filled with the polyurethane foam-molded portion.

  For the coupling and integration of the core material pad 1 and the surface layer molding pad 4, it is sufficient to provide the horizontal groove 37 and the transverse groove 38 as the concave groove 3. The horizontal groove filling portion 47 buried in the horizontal groove 37 is lateral to the surface layer forming pad 4 even when an external force as shown by an arrow in FIG. This is because the surface layer portion 42 and the transverse groove filling portion 48 buried in the transverse groove 38 are connected to each other, and the function can be exhibited as a stopper that the transverse groove filling portion 48 prevents. The portion of the transverse groove filling portion 48 that protrudes outward from the horizontal groove 37 hits the groove wall 38f of the transverse groove 38 to finish the desired cushion pad P that prevents the surface layer forming pad 4 from being peeled off. If the cushion pad is covered with a skin (not shown), a seat cushion on the rear seat of the vehicle is completed.

Here, it is more preferable that the groove 3 of the cushion pad P is provided with a longitudinal groove 36. The presence of the vertical groove filling portion 46 embedded in the vertical groove 36 that is longer than the groove depth of the horizontal groove 37 can strengthen the coupling between the horizontal groove filling portion 47 and the side surface layer portion 42 associated with the surface layer forming pad 4. Further, it is more preferable that the upper end 362 of the vertical groove 36 reaching the upper surface 2a side of the molding pad 2 is a vertical groove 36 as shown in FIG. This is because the vertical groove 36 also serves as a passage for degassing the foamed gas during foam molding of the surface layer molding pad 4. The thickness t of the surface layer forming pad 4 laminated and formed on the core pad side surface 1 c is smaller than the thickness of the upper surface layer portion 41. In the region where the thickness is thin, the problem that the excess foaming gas at the time of foam molding of the core pad 1 is likely to occur is likely to occur, but this can be solved.
In the figure, reference numeral P1 denotes a seat portion, reference numeral P2 denotes a connection portion with a backrest, reference numeral 4a denotes a surface of the surface layer forming pad, and reference numeral 43 denotes a tension in which the side surface layer portion 42 protrudes beyond the lower surface of the core pad 1. Reference numeral 10 denotes an opening of the core pad 1, and reference numeral 40 denotes an opening of the surface layer forming pad 4. A seat belt is attached to the overlapping openings 10 and 40.

(2) Manufacturing method of vehicle cushion pad The manufacturing method of the vehicle cushion pad is as follows. After the core pad 1 is set in the foaming mold 7 using the core pad 1 and the foaming mold 7, the foaming raw material g is injected. After closing the mold, a cushion pad P as shown in FIG. 10 is formed. Prior to manufacturing, the core pad 1 and the foaming mold 7 are prepared.

  As described above, the core pad 1 is arranged on the lower surface 2b of the molding pad, a horizontal groove 37 with a groove opening on one end exposed on one side surface 2c of the molding pad 2, and a cross or T-letter shape with respect to the horizontal groove 37. And the molding pad 2, the horizontal groove 37, and the transverse groove 38 are a base body for the cushion pad P that is integrally formed as a molded body of a non-breathable foam. It is a lump-shaped non-breathable foamed molded body, and is molded in advance prior to the production of the cushion pad. Here, the core pad 1 is for the cushion pad P as shown in FIGS. 5 and 10, and is provided with a vertical groove 36, a horizontal groove 37, a transverse groove 38, and a transverse groove 39.

  The foaming mold 7 used in the cushion pad manufacturing method is a split mold as shown in FIGS. 8 to 10 and includes an upper mold 9 (one split mold) and a lower mold 8 (other split mold). When the mold is closed from FIG. 8 to FIG. 9 using the hinge 71 as a fulcrum, the cavity C of the cushion pad P is formed by the mold surface 81 of the lower mold 8 having a large degree of dent and the mold surface 91 of the substantially flat upper mold 9. . 8 to 10, the design surface side of the cushion pad P is formed on the lower mold surface 81, and the back surface side of the cushion pad P is molded on the upper mold surface 91. The cushion pad P in FIG. 1 is molded upside down.

The cushion pad P shown in FIG. 5 is manufactured using the core pad 1 and the foaming die 7 as follows, for example.
First, the foaming mold 7 is brought into the mold open state. Subsequently, the core pad 1 is set on the upper mold 9 in the mold open state. The core material pad 1 is set so that the core material pad lower surface 1b is brought into contact with the upper mold surface 91 (FIG. 8).

Thereafter, polyurethane foam raw material g (hereinafter also simply referred to as “foaming raw material”) is injected and the mold is closed. A predetermined amount of the foaming raw material g is injected into the lower mold surface 81 using the injection hose NL or the like while the mold is open in FIG.
Subsequently, the upper die 9 is operated to close the die (FIG. 9). By closing the upper die 9 and the lower die 8, a cushion pad cavity C in which the core pad 1 is insert-set is formed. In the present embodiment, the mold is closed after injecting the foaming raw material g. However, the foaming raw material g can be injected after the mold is closed.

After closing the mold, move to foam molding of the main process. The mold closed state of FIG. 9 is maintained for a predetermined time, and the vertical groove 36, the horizontal groove 37, the transverse groove 38, and the transverse groove 39 shown in FIG. 5 are filled with a polyurethane foam molded portion, and the upper surface 1a and side surfaces of the core pad The surface layer molding pad 4 on which the polyurethane foam molding part is laminated on 1c is foam-molded to make the cushion pad P.
In the foam molding of the surface layer molding pad 4, the polyurethane foam raw material g enters the longitudinal grooves 36, the horizontal grooves 37, the transverse grooves 38, and the lateral grooves 39 to fill and form the polyurethane foam molding portion, and the upper surface 1a and side surfaces of the core pad The surface layer molding pad 4 is foam-molded so that the upper surface layer portion 41 and the side surface layer portion 42 of the polyurethane foam raw material g are laminated on 1c. The upper surface layer portion 41 and the side surface layer portion 42 that are the design surface side of the cushion pad P are laminated on the core material pad upper surface 1a and the core material pad side surface 1c, and the vertical groove 36, the horizontal groove 37, the transverse groove 38, And the vertical groove filling part 46 of the polyurethane foam molding part, the horizontal groove filling part 47, the transverse groove filling part 48, and the transverse groove filling part 49 become the surface layer molding pad 4 in the transverse groove 39 (FIGS. 4 to 6). The surface layer forming pad 4 integrated with the inserted core material pad 1 in such a manner that the horizontal groove filling portion 47, the transverse groove filling portion 48, etc. are fitted into the respective groove shapes such as the horizontal groove 37, the transverse groove 38, etc. Is foam-molded. The core pad lower surface 1b is exposed as shown.

Under the mold closed state, one end side groove opening of the horizontal groove 37 leads to the cavity C forming the side surface layer portion 42, and in foam molding of the surface layer forming pad 4, the foam raw material g is fed from the groove opening to the horizontal groove 37 and the transverse groove. 38. If the longitudinal groove 36 is provided, the periphery of the horizontal groove 37 into which the foaming raw material g permeates is widened, and the horizontal groove filling part 47 and the transverse groove filling part 48 of the polyurethane foam molding part can be well formed. Further, when the upper end 362 of the longitudinal groove 36 reaches the upper surface 2a side of the molding pad 2, the surface layer molding pad 4 is molded well, and the yield of the cushion pad P is improved. If it demonstrates in FIG. 4, the thickness of the side surface layer part 42 in the surface layer shaping | molding pad 4 will be set thinly. Therefore, it is difficult for the foaming raw material g to flow toward the overhanging portion 43 located at the tip of the side surface layer portion 42 during foam molding, and the foaming raw material g is cured without foaming at this portion during foam molding. In addition, excessive foaming gas cannot escape, and molding defects are likely to occur.
However, when the upper end 362 of the vertical groove 36 reaches the upper surface 2a side of the molding pad 2, a new passage for the groove depth h can be created (a in FIG. 4), and the passage of the foaming raw material g and surplus foaming gas can be improved. To do. In the foam molding process, as shown by the arrow in FIG. 9, the foaming raw material g rises and penetrates smoothly to the point of the horizontal groove 37 and the transverse groove 38 through the vertical groove 36. Although not shown, the foaming raw material g also flows toward the lateral grooves 39 in the process in which the foaming raw material g rises in the vertical groove 36.

As described above, the longitudinal groove filling portion 46, the horizontal groove filling portion 47, and the transverse groove filling portion 48 in which the foaming raw material g surely fills and fits the inside of each of the longitudinal groove 36, the horizontal groove 37, the transverse groove 38, and the transverse groove 39 is fitted. The surface layer molding pad 4 in which the lateral groove filling portion 49, the upper surface layer portion 41 and the side surface layer portion 42 are integrated is foam-molded. When foam molding of the surface layer molding pad 4 is finished and removed, a desired cushion pad P in which the core material pad 1 is embedded and integrated is obtained.
In the figure, reference numerals 89 and 99 are mold matching surfaces, and reference numeral 811 is a recess for forming a backrest connecting portion. Other configurations are the same as (1) the description of the cushion pad, and are omitted.

(3) Effects The cushion pad for a vehicle configured as described above and the manufacturing method thereof are a non-vented foam, and become a cushion pad P in which a polyurethane foam molded portion is laminated on a light core pad 1. Is achieved. When a polystyrene foam or polyethylene foam is used for the core pad 1, the core pad 1 can be made very light, and the cushion pad P can be further reduced in weight.

Further, the horizontal groove 37 and the transverse groove 38 are formed in the core pad 1, and the horizontal groove filling portion 47 and the transverse groove filling portion 48 of the polyurethane foam molded portion embedded in the horizontal groove 37 and the transverse groove 38 in the surface layer molding pad 4. When the surface layer forming pad back surface 4b and the core material pad 1 are not bonded, they can be integrated mechanically by combining them. That is, on the lower surface 2b of the molding pad 2, the horizontal groove 37 has a groove opening on one end side exposed on one side surface 2c of the molding pad 2, so that foam molding of the surface layer molding pad 4 and one end side of the horizontal groove filling portion 47 is the surface layer. It joins with the lower edge portion of the side surface portion 42 of the pad. Then, the transverse groove filling portion 48 coupled to the horizontal groove filling portion 47 prevents this from being applied to an external force that tries to peel off the surface layer forming pad 4. If the groove bottom 38e of the transverse groove 38 is deeper than the groove bottom 37e of the horizontal groove 37 and the transverse groove filling portion 48 is buried deeply, the surface layer forming pad 4 is more strongly peeled off from the core pad 1. I can stop. The bonding force between the core material pad 1 and the surface layer forming pad 4 is further increased. When the horizontal groove filling portion 47 and the transverse groove filling portion 48 are provided at necessary positions on the peripheral edge of the molding pad lower surface 2b at an appropriate interval, the core material pad 1 and the surface layer molding pad 4 covering this can be integrated. Become a rock.
The integration of the core material pad 1 and the surface layer forming pad 4 does not require the surface of the core material pad 1 to be roughened as in Patent Document 2. In foam molding of the surface layer molding pad 4, the horizontal groove filling portion 47, the transverse groove filling portion 48 and the like that fit into the concave groove 3 are simultaneously molded by foam molding of the surface layer molding pad 4, so that the cushion pad P can be easily manufactured. It has become. Nevertheless, the robustness due to the mechanical structural coupling of the horizontal groove filling portion 47 and the transverse groove filling portion 48 by fitting is ensured.

In order to hide the core pad 1 inside the cushion pad P, the lower edge portion of the side surface layer portion 42 of the surface layer forming pad 4 extends as shown in FIG. 1, and the protruding portion 43 is formed on the lower surface 2b of the forming pad. In many cases, the protruding portion 43 is easily turned by an external force. This is prevented by the horizontal groove filling portion 47 and the transverse groove filling portion 48.
Even if an external force as indicated by an arrow shown in FIG. 3B is applied to the overhanging portion 43, the horizontal groove filling portion 47 connected to the overhanging portion 43 transmits to the crossing groove filling portion 48, and the crossing groove filling portion 48 is subjected to the external force. Resist. The transverse groove filling portion 48 strikes against the groove wall 38f of the transverse groove 38 projecting outward from the horizontal groove 37 to prevent resistance, and the overhang portion 43 does not separate from the core pad 1 and The integration of the surface molding pad 4 is maintained.
Since the surface layer molding pad 4 autonomously creates the horizontal groove filling portion 47 and the transverse groove filling portion 48 by its own foam molding, the work load is not increased.

  Further, a horizontal groove 37 and a transverse groove 38 in which the horizontal groove filling portion 47 and the transverse groove filling portion 48 are embedded are integrally formed with the molding pad 2 as a non-breathable foamed molded body, and a surface film layer (skin) is formed on the molded body. When the layer) is formed, there is no possibility that the internal foam layer is exposed and gas escapes or becomes brittle.

Further, if the core pad 1 is provided with the vertical groove 36 and the surface layer forming pad 4 is provided with the vertical groove filling part 46, the vertical groove filling part 46 is coupled to the horizontal groove filling part 47, and the horizontal groove filling part 47 The binding force with the side surface layer portion 42 is increased. When the upper end 362 of the longitudinal groove 36 reaches the upper surface 2a side of the molding pad 2, the foaming raw material g smoothly rises in the cavity C for forming the side surface layer portion 42 during foam molding using the longitudinal groove 36. Advances and degass surplus foaming gas smoothly. This is useful for improving the yield of the cushion pad P.
In addition, when the core material pad 1 is provided with the lateral groove 39 and the surface layer forming pad 4 is provided with the lateral groove filling portion 49, the lateral surface layer portion 42 tends to shift upward or downward with respect to the core material pad 1 in FIG. However, the transverse groove filling portion 49 fitted in the transverse groove 39 prevents and prevents this. With respect to the core pad 1, the lateral surface layer portion 42 is not displaced not only in the horizontal direction in FIG.
As described above, the vehicle cushion pad and the manufacturing method thereof are extremely useful because they exhibit the various excellent effects described above.

  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. In the present embodiment, the transverse groove 38 protrudes outward from the horizontal groove 37 and is arranged in a cross shape or a T-shape with respect to the horizontal groove 37, but protrudes to one outer side of the horizontal groove 37. It may be arranged in a so-called L letter shape. The shape, size, number, material, and the like of the core material pad 1, the molding pad 2, the concave groove 3, the surface layer molding pad 4, the foaming mold 7, etc. can be appropriately selected according to the application.

1 Core material pad 1a Upper surface (upper surface of core material pad)
1c Bottom surface (underside of core pad)
2 Molding pad 2b Bottom surface (bottom surface of molding pad)
36 Longitudinal groove 37 Horizontal groove 38 Transverse groove 39 Horizontal groove 4 Surface layer molding pad 7 Foam type 9 Upper mold g Polyurethane foam raw material (foam raw material)

Claims (8)

On the lower surface of the block-shaped molding pad, there are a horizontal groove in which a groove opening on one end side is exposed on one side surface of the molding pad, and a transverse groove arranged in a cross shape, T letter shape, or L letter shape with respect to the horizontal groove. A core pad that is provided and the horizontal groove, the transverse groove, and the molding pad are integrally formed as a non-breathable foam molded article;
A vehicle cushion comprising: a polyurethane foam molded portion embedded in the horizontal groove and the transverse groove, and a surface layer molded pad provided with a polyurethane foam molded portion laminated on an upper surface and a side surface of the core pad. pad. A vertical groove integrally formed as a part of the molded body related to the core pad is provided in the vertical direction on the side surface near the lower end of the molding pad, and is connected to the horizontal groove at the lower end of the vertical groove. The vehicle seat pad according to claim 1, wherein the groove is filled with a polyurethane foam molded portion. The vehicle cushion pad according to claim 2, wherein the non-breathable foamed molded body is a molded body of foamed polypropylene or polystyrene, and the upper end of the longitudinal groove reaches the upper surface side of the molding pad. A plurality of the vertical grooves are provided apart from each other on one side surface of the molding pad, and a horizontal lateral groove connecting adjacent vertical grooves is integrally formed as a part of the molded body related to the core pad, and The vehicular cushion pad according to claim 2 or 3, wherein the horizontal groove is filled with a polyurethane foam molded portion together with the vertical groove. On the lower surface of the block-shaped molding pad, there are a horizontal groove in which a groove opening on one end side is exposed on one side surface of the molding pad, and a transverse groove arranged in a cross shape, T letter shape, or L letter shape with respect to the horizontal groove. The core pad, which is provided and the horizontal groove, the transverse groove, and the molding pad are integrally formed as a non-breathable foam molded body, is set in one divided mold of the foaming mold, and then polyurethane foam Foam molding of a surface layer molding pad comprising a polyurethane foam molding part filling the horizontal groove and the transverse groove through injection of raw materials and mold closing, and a polyurethane foam molding part laminated on the top and side surfaces of the core pad. A method for manufacturing a cushion pad for a vehicle. A longitudinal groove integrally formed as a part of the molded body related to the core pad is provided in a vertical direction on a side surface near the lower end of the molding pad, and the core pad is connected to the horizontal groove at the lower end of the longitudinal groove. 6. The surface layer molding pad having a polyurethane foam molding portion that fills the longitudinal groove together with the horizontal groove and the transverse groove is foam-molded after the core material pad is set in one divided mold of the foaming mold. The manufacturing method of the cushion pad for vehicles as described. The non-breathable foamed molded product is a molded product of foamed polypropylene or foamed polystyrene, and the core pad in which the upper end of the vertical groove reaches the upper surface side of the molding pad is set in one split mold of the foaming type. Item 7. A method for manufacturing a vehicle cushion pad according to Item 6. A plurality of the vertical grooves are provided apart from each other on one side of the molding pad, and a horizontal lateral groove that connects adjacent vertical grooves is integrally formed as a part of the molded body related to the core pad. The method of manufacturing a cushion pad for a vehicle according to claim 6 or 7, wherein the surface layer molding pad including a polyurethane foam molding portion that fills the lateral groove together with the groove is foam-molded.

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