JP2018029655A - Vehicle seat member and production method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method of a vehicle seat member capable of obtaining a vehicle seat member with high dimension accuracy.SOLUTION: A vehicle seat member 10 having a frame material 20 and a foam resin molding body 30 in which the frame material 20 is embedded, is produced. Then, in plan view of the vehicle seat member 10, the frame material 20 is arranged in a molding tool 7 so that the frame material 20 is arranged along a contour S of the vehicle seat member 10. Then, in the molding tool 7, the foam resin molding body 30 comprising a frame-shaped part 35 in which the frame material 20 is embedded and which forms a contour S of the vehicle seat member 10, and an extension part 36 extending inward from the frame-shaped part 35 so as to build the frame-shaped part 35 in inside of the frame-shaped part 35, is molded. In the molding time, a slit 37A for dividing the extension part 36 along a direction crossing the extension direction L where the extension part 36 extends, is molded on the extension part 36.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a vehicle seat member and a method for manufacturing the same.

  As a vehicle seat member for an automobile or the like, for example, a vehicle seat member in which a frame material is integrally formed with a foamed resin molded body is known (see, for example, Patent Documents 1 and 2).

  In Patent Document 3, a vehicle seat member manufacturing method in which a frame member provided with a latch for fixing to a vehicle and a connecting member for connecting it is embedded in a foamed particle molded body and integrally molded. Is disclosed. The connecting member is embedded in the front side of the foamed particle molded body along the longitudinal direction of the vehicle seat member. In Patent Document 3, a notch directed from the pillar portion to the outside in the longitudinal direction is formed in the longitudinally outward portion of the vehicle seat member in the foamed particle molded body portion in which the pillar portion of the latch is embedded. It is described.

JP 2001-161508 A International Publication No. WO2015 / 159691 International Publication WO2016 / 042759

  As described above, in the vehicle seats described in Patent Documents 1 to 3, the frame material is integrally formed inside the foamed resin molded body constituting the vehicle seat member. Since the frame material and the foamed resin molding are made of different materials, their thermal expansion coefficients are different. For this reason, the degree of thermal expansion and thermal contraction differs between the portion of the foamed resin molded body in which the frame material does not exist and the portion of the foamed resin in which the frame material is embedded.

  Therefore, for example, the portion of the foamed resin in which the frame material is not present in the foamed resin molded body due to heat dissipation during demolding of the foamed resin molded body after molding, heat input to the vehicle seat member, or the like has a predetermined shape. It is assumed that the material is slightly deformed.

  The present invention disclosed in the present specification to solve the above problems is a method for manufacturing a vehicle seat member including a frame material and a foamed resin molded body in which the frame material is embedded, and the vehicle seat An arrangement step of arranging the frame material in a mold so that the frame material is arranged along the contour of the vehicle seat member in plan view of the member; and the frame material is embedded in the mold And a foam including a frame-shaped portion that forms an outline of the vehicle seat member, and an extending portion that extends inward from the frame-shaped portion so as to pass through the frame-shaped portion inside the frame-shaped portion. A molding step of molding a resin molded body, and a notch groove, a cut, or the extension portion along a direction intersecting an extension direction in which the extension portion extends during the molding step. A notch that breaks Characterized by forming the Kinobezai unit.

  In the method for manufacturing a vehicle seat member, the frame-shaped portion of the foamed resin molded body in which the frame material is embedded and the extended portion that extends inside the frame-shaped portion and does not have the frame material are apparent. The amount of heat shrinkage is different. As a result, compressive stress and tensile stress act as thermal stress nonuniformly on the extension part surrounded by the frame-like part, and the extension part is easily deformed. In the present invention, this deformation can be suppressed. .

  That is, in the present invention, during the molding step, the extending portion extending inside the frame-shaped portion is molded with a notch groove or a cut along a direction intersecting the extending direction. The stress acting on the surface of the extension part due to the contraction can be released, and deformation of the extension part can be suppressed. In addition, by forming a notch that divides the extending portion into the extending portion along the direction intersecting the extending direction, the extending portion is configured by the divided dividing portion, and the dividing portion is Will have a free end. Thereby, even if the extended part is thermally contracted, the thermal stress acting on the extended part can be suppressed. As a result, a vehicle seat member with high dimensional accuracy can be manufactured.

  As a more preferable aspect, the frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous, and in the molding step, the extending portion is defined as the opposed portion. It shape | molds so that it may extend over between.

  Here, since both sides of the extended portion are constrained by the portion of the frame-like portion in which the continuous portion of the frame material is embedded, such an extended portion is easily deformed by heat shrinkage. Even in such a case, according to this aspect, it is possible to suppress deformation of the extending portion by forming a notch groove, a cut, or a notch in the extending portion.

  As a more preferable aspect, the outline of the vehicle seat member in the plan view has a shape having a short side direction and a long side direction, and in the molding step, the extending portion is opposed to the frame-like portion. A portion is formed so as to include at least a first extending portion extending along the longitudinal direction, and the notch groove, the cut line, or the cut is formed in the first extending portion. .

  Here, the first extending portion formed along the longitudinal direction is easily deformed by heat shrinkage. According to this aspect, when forming the first extending portion, a notch groove, a cut, or By forming the notch, it is possible to suppress deformation of the extending portion due to heat shrinkage.

  As a more preferable aspect of the notch groove, the notch groove is formed so as to spread from the groove bottom toward the groove opening. According to this aspect, by forming the notched groove so as to spread from the groove bottom toward the groove opening, the thermal stress acting along the extending direction on the surface of the extending portion and the vicinity thereof at the time of thermal contraction. And the deformation of the extension can be suppressed.

  As a more preferable aspect, the frame member is circulated along the contour of the vehicle seat member. According to this aspect, since the frame member circulates along the contour of the vehicle seat member, the strength of the vehicle seat member can be increased. Here, when the frame material is circulated along the contour of the vehicle seat member, both sides of the extending portion are constrained and easily deformed by thermal contraction. Even in such a case, according to this aspect, even if any one of the notch groove, the notch, and the notch is formed in the extending portion, the extension portion is extended by the notch groove, the notch, or the notch. The deformation of the part can be effectively suppressed.

  In this specification, the vehicle seat member is further disclosed as the present invention. A vehicle seat member according to the present invention is a vehicle seat member including a frame material and a foamed resin molded body in which the frame material is embedded, and the frame material is a plan view of the vehicle seat member. The foamed resin molded body is disposed along the contour of the vehicle seat member, and the foamed resin molded body embeds the frame material and forms the contour of the vehicle seat member; and the frame-shaped portion An extension part extending inwardly from the frame-like part so as to pass through the frame-like part on the inner side of the extension part, and the extension part has an extension direction in which the extension part extends A notch groove, a cut, or a cut that divides the extending portion is formed along the intersecting direction.

  When heat is input to the vehicle seat member (or when the input heat is dissipated), the frame-shaped portion in which the frame material is embedded in the foamed resin molded body, and the inside of the frame-shaped portion The apparent thermal expansion amount (thermal contraction amount) differs from the extended portion where the frame material does not exist. As a result, compressive stress and tensile stress act as thermal stress nonuniformly on the extension part surrounded by the frame-like part, and the extension part is easily deformed. In the present invention, this deformation can be suppressed. .

  That is, in the present invention, a notch groove or a cut is formed on the surface of the extending portion along the direction intersecting the extending direction in the extending portion extending inside the frame-shaped portion. The applied thermal stress can be released and deformation of the extension can be suppressed. In addition, by forming a notch that divides the extending portion in the extending portion along the direction intersecting the extending direction, the extending portion is constituted by the divided dividing portion, and the dividing portion is Will have a free end. Thereby, even if the extension part is thermally expanded and contracted, the thermal stress acting on the extension part can be suppressed. As a result, the dimensional accuracy of the vehicle seat member can be ensured even when any one of a notch groove, a cut, and a cut is formed in the extending portion.

  As a more preferred aspect, the frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous, and the extending portion extends between the opposed portions. It is formed to extend.

  Here, since both sides of the extended portion are restrained by the frame-like portion in which the continuous portion of the frame material is embedded, such an extended portion is particularly easily deformed by thermal expansion and thermal contraction. Even in such a case, according to this aspect, it is possible to suppress deformation of the extending portion by forming a notch groove, a cut, or a cut in the extending portion.

  As a more preferred aspect, the outline of the vehicle seat member in the plan view is a shape having a short side direction and a long side direction, and the extending portion extends over a portion where the frame-like portion faces. A first extending portion along the longitudinal direction is included, and the cutout groove, the cut, or the cut is formed in the first extending portion. The first extending portion formed along the longitudinal direction is easily deformed by thermal expansion and contraction. According to this aspect, a notch groove, a cut, or a cut is formed in the first extending portion. Thus, deformation of the extending portion can be suppressed.

  As a more preferred embodiment of the notch groove, the notch groove is formed so as to expand from the groove bottom toward the groove opening. According to this aspect, by forming the notched groove so as to spread from the groove bottom toward the groove opening, it acts along the extending direction on the surface of the extending portion and the vicinity thereof during thermal expansion and contraction. The thermal stress to be released can be released, and deformation of the extended portion can be suppressed.

  As a more preferred aspect, the frame material circulates along the contour of the vehicle seat member. According to this aspect, since the frame member circulates along the contour of the vehicle seat member, the strength of the vehicle seat member can be increased. Here, when the frame member is circulated along the contour of the vehicle seat member, both sides of the extending portion are constrained and easily deformed due to thermal expansion and contraction. Even in such a case, according to this aspect, even if any one of the cutout groove, the cut, and the cut is formed in the extending portion, the cutout groove, the cut, or the cut is formed. Thus, the deformation of the extending portion can be effectively suppressed.

  According to the method for manufacturing a vehicle seat member according to the present invention, a vehicle seat member with high dimensional accuracy can be obtained. Further, according to the vehicle seat member of the present invention, the dimensional accuracy of the vehicle seat member is ensured even when heat is input to the vehicle seat member or when the input heat is dissipated. can do.

It is the typical perspective view which looked at the vehicle seat member concerning a 1st embodiment of the present invention from the upper part side. It is the typical perspective view which looked at the vehicle seat member shown in FIG. 1 from the lower side. It is a top view of the vehicle seat member shown in FIG. It is a left view of the vehicle seat member shown in FIG. It is a typical perspective view for demonstrating the manufacturing method of the vehicle seat member shown in FIG. It is typical sectional drawing in the position corresponding to the II arrow directional cross section shown in FIG. (A) is a cross-sectional view of a state where pre-foamed resin particles are filled in a mold, and (b) is a foamed resin molded body obtained by foaming the pre-foamed particles from the state shown in (a). It is sectional drawing of the state which carried out, (c) is the figure which showed the state which removed the foamed resin molding from the state shown to (b) from the shaping | molding die. It is a figure for demonstrating the manufacturing method of the vehicle seat member used as a comparative example, (a) is sectional drawing of the state which expanded the pre-expanded particle and shape | molded the foamed resin molding, (b) These are the figures which showed the state which removed the foamed resin molding from the state shown to (a) from a shaping | molding die. It is the typical perspective view which looked at the vehicle seat member concerning a 2nd embodiment of the present invention from the upper part side. (A) is a notch groove shown in Drawing 8, and typical sectional drawing of the neighborhood, (b)-(e) is a figure for explaining a modification of a notch groove shown in (a). (F) is a schematic cross-sectional view of the cut and its vicinity. It is the typical perspective view which looked at the vehicle seat member concerning other embodiments of the present invention from the lower part side. It is the typical perspective view which looked at the vehicle seat member which concerns on the modification of the vehicle seat member shown in FIG. 10 from the upper side. It is the typical perspective view which looked at the vehicle seat member concerning other embodiments of the present invention from the lower part side. It is the typical perspective view which looked at the vehicle seat member concerning other embodiments of the present invention from the lower part side.

  Hereinafter, several embodiments of a vehicle seat member and a vehicle seat according to the present invention will be described with reference to the drawings. However, the scope of the present invention is not limited to individual embodiments.

<First Embodiment>
1. About Vehicle Seat Member 10 A first embodiment of a vehicle seat member and a method for manufacturing the same will be described with reference to FIGS.
As shown in FIGS. 1 and 2, the vehicle seat member 10 includes a frame material 20 and a foamed resin molded body 30 in which at least a part of the frame material 20 is embedded as a basic configuration.

  Although there is no restriction | limiting in particular in the whole shape of the vehicle seat member 10, As shown in FIG. 3, the shape which is a rectangle by planar view is common. In this specification, a rectangle refers to a rectangle such as a rectangle or a square, and is not limited to a rectangle or a square, but may be a trapezoid or a parallelogram. In the present specification, the rectangle includes a case where the rectangle is a rough rectangle. For example, the corner may be rounded, or a part or all of the sides constituting the rectangle may be bent.

  In the present embodiment, as shown in FIG. 3, the contour S in a plan view of the vehicle seat member 10 is a rectangle having a short side and a long side, and has a shape having a short side direction and a long side direction. . The contour S includes, as four sides, a right edge portion sR and a left edge portion sL constituting a short side, a front edge portion sF and a rear edge portion sB constituting a long side, and corner portions constituting four corners. sC. In the present embodiment, the front, rear, left, and right refer to directions when the vehicle is viewed from the vehicle in a state where a passenger is seated in the vehicle.

  For example, as shown in FIG. 4, the vehicle seat member 10 of the present embodiment includes an upper seat member 50 such as a cushion material as appropriate from the upper surface 11 of the vehicle seat member 10, that is, the upper surface 31 side of the foamed resin molded body 30. Can be stacked to form the vehicle seat 1. Further, the vehicle seat member 10 may be covered with a cushion material or the like by an appropriate exterior material to form the vehicle seat 1.

1-1. About Frame Material 20 As shown in FIGS. 1 and 2, the frame material 20 is embedded in the foamed resin molded body 30 in order to give the required shape retention and strength. The frame material 20 is usually composed of a material whose dimensions do not substantially change compared to the foamed resin molded body 30 under the conditions for molding the foamed resin molded body 30, for example, a metal material such as steel or aluminum. is there.

  The frame member 20 includes first and second frame portions 21 and 22 that extend into the foamed resin molded body 30 along the contour S of the vehicle seat member 10 in plan view, and the first and second frame portions. And a pair of pedestal portions 23 and 23 connected to the end portions of 21 and 22.

  The frame member 20 further includes a front locking portion 24 attached to each pedestal portion 23 and a rear locking portion 25 attached to the second frame portion 22. In the present embodiment, as the first and second frame portions 21 and 22 and the front and rear locking portions 24 and 25, for example, steel or aluminum wire (wire) having a diameter of about 3 to 6 mm is used. For example, it may be a metal strip-shaped or tubular steel material. Further, the frame material 20 may be manufactured from a steel plate by punching and press forming.

  The first frame portion 21 of the frame material 20 is disposed in the vicinity of the center of the front edge portion sF, and the second frame portion 22 includes both sides of the front edge portion sF, the right edge portion sR, and the left side. It is disposed in the vicinity of the edge portion sL, the rear edge portion sB, and each corner portion sC. The frame material 20 is embedded in a portion slightly inside from the outer peripheral surface 33 of the foamed resin molded body 30 forming the contour S so as to follow the contour S of the vehicle seat member 10.

  In this manner, the frame material 20 continuously circulates along the contour S of the vehicle seat member 10 by the first and second frame portions 21 and 22 and the pair of pedestal portions 23 and 23 connecting them. ing. In the present embodiment, the frame member 20 continuously circulates along the contour S of the vehicle seat member 10. For example, the frame member 20 extends along the contour S of the vehicle seat member 10. You may circulate intermittently. That is, not only in this form, the skeleton part may be arranged only in a part along the contour S. For example, the 2nd frame part 22 may be arrange | positioned along the back edge part sB, without being connected with the base parts 23 and 23. FIG. Further, the number of frame parts constituting the frame material 20 is not limited to two, and the number may be one or three or more.

  The front locking part 24 and the rear locking part 25 of the frame material 20 are parts for locking the vehicle seat member 10 to the vehicle. The front locking portion 24 is connected to the pedestal portion 23 by welding or adhesion, for example, and protrudes downward from the pedestal portion 23. The front end portion 24 a of the front locking portion 24 is curved in a substantially U shape, is exposed from the foamed resin molded body 30, and the base end portion 24 b is embedded in the foamed resin molded body 30 together with the pedestal portion 23. . More specifically, the entire base end portion 24 b is embedded in the foamed resin molded body 30. Thereby, even when a force in the pulling-out direction is applied when the vehicle seat member 10 of the present embodiment is locked to the vehicle via the distal end portion 24a of the front locking portion 24, the front locking portion 24 is applied. Is held by the foamed resin molded body 30 and can increase resistance to force in the pulling direction.

  Further, the rear locking portion 25 protrudes rearward from the central portion 22b along the rear edge portion sB in the second skeleton portion 22. The distal end portion 25 a of the rear locking portion 25 is curved in a substantially U shape, is exposed from the foamed resin molded body 30, and the base end portion 25 b is embedded in the foamed resin molded body 30.

  In this embodiment, the front end portions 24a and 25a of the front engaging portion 24 and the rear engaging portion 25 are formed by bending a wire rod into a substantially U shape, but the structure is not limited to this. What is necessary is just to make it the structure which can be latched according to a structure.

  In the present embodiment, the front locking portion 24 is connected to both the first and second frame portions 21 and 22 via the pedestal portion 23. However, the front locking portion 24 is not limited to this form, and is connected directly to both the first or second frame portions 21 and 22 without using the pedestal portion 23 like the rear locking portion 25. May be. Moreover, the number of the front latching | locking parts 24 is not specifically limited, One may be sufficient and three or more may be sufficient. One of the front locking part 24 and the rear locking part 25 may not exist.

1-2. About Foamed Resin Molded Body 30 As shown in FIGS. 1 and 2, the foamed resin molded body 30 is an in-mold foam molded body of foamed resin. The foamed resin is not particularly limited, but usually, a foamed thermoplastic resin is used. Preferably used. The expansion ratio can be appropriately adjusted according to the type of the foamed resin, but is generally about 10 to 50 times, typically about 20 to 40 times.

  The foamed resin molded body 30 is formed with an upper surface 31 on the side on which a vehicle occupant sits and a bottom surface 32 on the side fastened to the vehicle. The foamed resin molded body 30 includes a frame-shaped portion 35 that embeds the frame material 20 and forms the outline S of the vehicle seat member 10 in a plan view of the vehicle seat member 10. The frame-shaped portion 35 includes a front portion 35a positioned in front of the seat and a rear portion 35b formed integrally with the front portion 35a and inclined rearward with the vehicle seat member 10 attached. It is configured. When the vehicle seat member 10 is incorporated in a vehicle, the front portion 35a of the foamed resin molded body 30 supports the upper leg portion of the occupant and the rear portion 35b supports the heel portion of the occupant.

  Specifically, as shown in FIG. 4, the upper surface 31 of the foamed resin molded body 30 is a curved surface that is recessed downward so that the vicinity of the rear end of the front portion 35 a is the deepest portion in the illustrated embodiment. Thus, the upper leg member 50 is formed so as to hold the occupant's upper leg and buttocks. However, the shape and thickness of the foamed resin molded body 30 can be variously changed depending on the shape of the vehicle main body side to which the vehicle seat member 10 is attached, and is not limited to the illustrated embodiment. For example, the upper surface 31 of the foamed resin molded body 30 may have a substantially flat shape.

  The foamed resin molded body 30 includes an extending portion 36 that extends from the frame-shaped portion 35 to the inside thereof so as to pass through the frame-shaped portion 35 inside the frame-shaped portion 35. More specifically, in the present embodiment, the frame member 20 has a second frame portion 22 (continuous portion) in which opposed portions 22a and 22a facing each other across the space inside the frame-shaped portion 35 are continuous. ing. The extending portion 36 is formed so as to extend between the facing portions 22a and 22a.

  Such an extended portion 36 is a reinforcing portion that reinforces the vehicle seat member 10, and by forming the extended portion 36 in the space inside the frame-shaped portion 35, the front portion 35 a of the foamed resin molded body 30 and The rear portions 35b are formed with lightening portions 38a and 38b, respectively. The lightening portions 38a and 38b reduce the weight of the foamed resin molded body 30, and other members constituting the vehicle seat (for example, cushion materials that are more easily elastically deformed than the foamed resin molded body 30, members of console boxes, etc. ) For the purpose of accommodating.

  As shown in FIGS. 1 to 3, the extending portion 36 of the foamed resin molded body 30 is divided into the extending portion 36 along the direction intersecting the extending direction L in which the extending portion 36 extends. A cut 37A is formed. More specifically, the extending direction L in which the extending part 36 extends coincides with the longitudinal direction of the vehicle seat member 10, and the cut 37 </ b> A is along the short direction perpendicular to the longitudinal direction. Is formed. Thereby, the extension part 36 will be comprised by two part part 36a, 36a, and the front end side of the part part 36a becomes a free end. Here, the width of the cut 37A is not limited as long as the extending portion 36 is divided. However, from the viewpoint of securing the strength of the foamed resin molded body 30, the width of the cut 37A (that is, the gap between the divided portions 36 and 36) is the longitudinal direction (extension) of the extended portion 36 in a state where the cut 37A is not formed. 20% or less is preferable with respect to the length in the direction L), more preferably 10% or less, still more preferably 5% or less, and further preferably 2% or less.

  In the present embodiment, the cut 37A is formed along the short direction perpendicular to the longitudinal direction. However, if the cut 37A can divide the extending portion 36, the extending direction L A notch 37A may be provided along a direction that is inclined with respect to the crossing.

  Furthermore, in the present embodiment, one extending portion 36 is formed along the longitudinal direction, but a plurality of extending portions 36 may be provided as necessary, and the short direction or these directions are different. One or more extending portions may be provided along any direction.

  Here, when heat is input to the vehicle seat member 10 (or when the input heat is dissipated), the frame-shaped portion 35 in the state in which the frame material 20 is embedded in the foamed resin molded body 30; The apparent amount of thermal expansion (heat shrinkage) differs from the extended portion 36 that extends inside the frame-shaped portion 35 and does not have the frame material 20. As a result, the extending portion 36 surrounded by the frame-shaped portion 35 is subjected to compressive stress and tensile stress as thermal stress in a non-uniform manner and easily deforms so that the center of the extending portion 36 is curved upward, for example. . In particular, such a phenomenon is remarkable in the extending portion 36 formed along the longitudinal direction.

  However, in the present embodiment, by forming the notch 37A that divides the extending portion 36 into the extending portion 36 that extends inside the frame-like portion 35, the extending portion 36 is divided into divided portions 36a, 36a, each dividing part 36a has a free end. Thereby, even if the extension part 36 is thermally expanded and contracted, the thermal stress which acts on the extension part 36 can be suppressed, and the dimensional accuracy of the vehicle seat member 10 can be ensured.

  In particular, in the present embodiment, a structure in which both sides of the extending portion 36 are constrained in the portion of the frame-like portion 35 in which the second framework portion 22 is embedded is adopted. For this reason, the extending part 36 is particularly easily deformed by thermal expansion and thermal contraction. When the frame material 20 continuously circulates along the contour S of the vehicle seat member 10, the extending portion 36 is further easily deformed. Even in such a case, in the present embodiment, as described above, by forming the notch 37A in the extending portion 36, each divided portion 36a is independently expanded and extended along the extending direction L. Since it contracts, the deformation of the extending portion 36 can be more effectively suppressed.

2. About the manufacturing method of the vehicle seat member 10 The manufacturing method of the vehicle seat member 10 is demonstrated below, referring FIG. 5 and FIG. In FIG. 5, the frame material 20 is indicated by a solid line for convenience. As shown in FIG. 5, when manufacturing the vehicle seat member 10 of the present embodiment, the frame material 20 is disposed in the cavity 73 of the molding die 7. Next, after filling the pre-expanded resin particles 30A obtained by pre-expanding the expandable resin particles containing the resin and the foaming agent, the pre-expanded resin particles 30A are expanded by supplying steam into the mold 7 and expanded. The resin molded body 30 is molded. Thereafter, after cooling the foamed resin molded body 30 in the mold 7, the foamed resin molded body 30 is removed from the mold 7 together with the frame material 20, and the heat remaining in the foamed resin molded body 30 is radiated (cooled). ).

  By the way, the foamed resin molded body 30 usually has a property of shrinking slightly when the residual heat at the time of foam molding is dissipated after demolding. On the other hand, the frame material 20 made of a material such as metal has no substantial dimensional change compared to the foamed resin molded body 30 before and after the molding of the foamed resin molded body 30. Therefore, as shown in FIG. 7A, the foamed resin molded body 30 is molded with the molding die 7 including the first die 71 and the second die 72, and as shown in FIG. The foamed resin molded body 30 is thermally contracted until the foamed resin molded body 30 is demolded and the foamed resin molded body 30 releases heat. At this time, since both sides of the extending portion 36 where the frame material 20 does not exist are restrained by the frame-like portion 35 where the frame material 20 exists, the extending portion 36 is not subjected to compressive stress or tensile stress as thermal stress. It acts uniformly and the extending part 36 is easily deformed so as to bend upward from the center. And the deformation | transformation state of the foamed resin molding 30 after a shaping | molding will be hold | maintained even after heat radiation.

  In view of such points, in the present embodiment, the vehicle seat member 10 is manufactured as follows. First, the frame material 20 is prepared. The structure and material of the frame material 20 are as described above. Next, as shown in FIG. 5, the frame material 20 is placed in the mold 7 so that the frame material 20 is arranged along the contour S of the vehicle seat member 10 in a plan view of the vehicle seat member 10. Arrange (arrangement process).

  As shown in FIGS. 5 and 6A, the molding die 7 includes a first die 71 and a second die 72, and when the first die 71 and the second die 72 are clamped, In addition, a cavity 73 corresponding to the foamed resin molded body 30 is formed. The first mold 71 has a partition wall along the direction (short direction) intersecting the extending direction L (longitudinal direction) in which the extending part 36 extends in accordance with the forming of the extending part 36. 74 is formed.

  Next, as shown in FIG. 6A, after the first mold 71 and the second mold 72 in which the frame material 20 is arranged are temporarily clamped (cracked), the foamability including a resin and a foaming agent is included. The pre-foamed resin particles 30A obtained by pre-foaming the resin particles are filled and clamped.

  Next, as shown in FIG. 6 (b), the inside of the cavity 73 of the mold 7 is heated with steam or the like to secondary-foam the pre-foamed resin particles 30A, filling the gaps between the pre-foamed resin particles 30A, The pre-foamed resin particles 30A are integrated by fusing each other to form the foamed resin molded body 30 (molding step).

  Thereby, the foamed resin molded body 30 including the frame-shaped part 35 and the extending part 36 can be molded in the mold 7. The molded frame portion 35 embeds the frame material 20 and forms the contour S of the vehicle seat member 10. The formed extension part 36 extends inward from the frame-like part 35 so as to pass through the frame-like part 35 inside the frame-like part 35. At the same time, the partition wall 74 is formed with a notch 37A that divides the extending portion 36 along the direction intersecting the extending direction L in which the extending portion 36 extends. The

  Next, the foamed resin molded body 30 in the mold 7 is cooled by water cooling or standing to cool. Furthermore, the foamed resin molded body 30 can be removed from the mold 7 to obtain the vehicle seat member 10 of the present embodiment in which the foamed resin molded body 30 and the frame material 20 are integrated. Here, after removing the foamed resin molded body 30 from the middle of the mold 7, the foamed resin molded body 30 contracts by releasing the residual heat after molding.

  In the embodiment, the extended portion 36 is formed by a pair of divided portions 36a and 36a by forming a cut 37A for dividing the extended portion 36 along a direction intersecting the extending direction L. Each part 36a has a free end. Thereby, even if the extending part 36 is thermally shrunk, each divided part 36a is shrunk independently, so that the thermal stress acting on the extending part 36 can be suppressed. As a result, the vehicle seat member 10 with high dimensional accuracy can be manufactured.

  In the present embodiment, as shown in FIG. 5, the frame material 20 has a second frame portion 22, and the second frame portion 22 is opposed to each other with a space inside the frame-shaped portion 35 interposed therebetween. 22a and 22a become the continuous part which continued. When the foamed resin molded body 30 is molded, the extending portion 36 is molded so as to extend between the facing portions 22a and 22a. Therefore, since both sides of the extended portion 36 are originally restrained by the portion of the frame-like portion 35 in which the second frame portion 22 of the frame material 20 is embedded, the extended portion 36 is easily deformed by thermal contraction. . In particular, since the frame member 20 is continuously circulated along the contour S of the vehicle seat member 10, such deformation is likely to occur. Even in such a case, in the present embodiment, such a deformation can be suppressed by forming the notches 37A in the extending portion 36 during the forming step.

Second Embodiment
Hereinafter, a vehicle seat member 10 and a method for manufacturing the same according to a second embodiment of the present invention will be described with reference to FIGS. 8 and 9. The vehicle seat member 10 according to the second embodiment is different from the first embodiment in that notched grooves 37B or cuts 37C are provided in the extending portion 36 instead of the notches 37A. Therefore, the same configurations as those of the first embodiment are denoted by the same reference numerals and detailed description thereof is omitted. As used herein, “notch” refers to what is formed so as to divide the extended portion, and “notch groove” and “cut” are formed so as not to divide the extended portion. Say.

  As shown in FIG. 8, in the present embodiment, a notch groove 37 </ b> B is formed in the extending portion 36 along the direction intersecting the extending direction L in which the extending portion 36 extends. More specifically, in this embodiment, the extending part 36 is formed along the longitudinal direction, and the notch groove 37B is formed along the short direction perpendicular to the longitudinal direction. In addition, the direction in which the notch groove 37B is formed is not limited as long as it intersects the extending direction L in which the extending portion 36 extends, similarly to the notch 37A.

  As shown in FIG. 9A, the notch groove 37B is formed so as to expand from the groove bottom 37a toward the groove opening 37b in a cross section orthogonal to the extending direction L in which the notch groove 37B extends. ing.

  Thus, in the present embodiment, the cutout groove 37B extends from the groove bottom 37a toward the groove opening 37b. Thereby, during thermal expansion and contraction, the thermal stress (tensile stress or compressive stress) acting along the extending direction L on the surface of the extending portion 36 and the vicinity thereof is released, so that the extending portion 36 is curved. Thermal deformation can be suppressed.

  Here, the notch groove 37B provided in the extending portion 36 is desirably provided at a position where the amount of thermal deformation of the extending portion 36 is the largest in a state where the notched groove 37B is not formed in the extending portion 36. Of the surfaces of the extending portions 36 that are deformed so as to be curved, it is desirable to provide them on the convex surface. Thereby, the thermal deformation of the extension part 36 can be suppressed more effectively. Further, a plurality of cutout grooves 37 </ b> B may be formed side by side in the extending direction L of the extending portion 36. Accordingly, it is possible to more efficiently suppress thermal deformation such that the extending portion 36 is curved by the plurality of notch grooves 37B having a shallower depth, and the strength of the extending portion 36 can be ensured. In particular, when a plurality of cutout grooves 37B are provided, each cutout groove 37B is formed such that the groove depth of each cutout groove 37B becomes shallower from the end of the extending portion 36 toward the center. It is more preferable.

  In the present embodiment, as a modification of the notch groove 37B, for example, as shown in FIG. 9B, the groove bottom portion 37a may be formed as a concave curved surface. Thereby, the stress concentration of the groove bottom part 37a can be reduced. Furthermore, as a modification of the notch groove 37B, as shown in FIG. 9C or FIG. 9D, the notch groove 37B may have a trapezoidal or rectangular groove in cross section. . Further, as shown in FIG. 9E, the groove bottom portion 37a of the rectangular cutout groove 37B may be formed of a concave curved surface. Further, as shown in FIG. 9F, a cut line (slit) 37C may be used instead of the cutout groove 37B.

  When the vehicle seat member 10 is manufactured, the frame material 20 is disposed so as to be positioned in the cavity of the molding die, as in the first embodiment. Next, after filling the pre-expanded resin particles obtained by pre-expanding the expandable resin particles containing the resin and the foaming agent, the pre-expanded resin particles are expanded by supplying steam into the molding die 7 and foamed resin molding The body 30 is molded. In the present embodiment, instead of providing the partition wall 74 in the first mold 71 shown in FIG. 6A, the first mold 71 is provided with a protruding portion that protrudes toward the second mold 72 in accordance with the notch groove 37B. . Thereby, the notch groove 37 </ b> B can be formed in the extending portion 36 of the foamed resin molded body 30. When the cut 37C is provided, a thin plate portion protruding toward the second mold 72 according to the shape of the cut 37C is provided in the first mold 71.

  Thereafter, the foamed resin molded body 30 is removed from the mold together with the frame material 20, and the foamed resin molded body 30 is dissipated. In the present embodiment, the extending portion 36 extending inside the frame-shaped portion 35 is formed by forming a notch groove 37 </ b> B or a cut 37 </ b> C along the direction intersecting the extending direction L. The thermal stress acting on the surface of the portion 36 can be released, and deformation of the extending portion 36 can be suppressed.

<Other embodiments>
Hereinafter, other embodiments of the present invention will be described with reference to FIGS. Note that, among the configurations of the vehicle seat member 10 according to these other embodiments, configurations common to the first embodiment and the second embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 10, in this embodiment, the extending portion 36 of the vehicle seat member 10 includes a first extending portion 36A extending in the longitudinal direction and two second extending portions extending in the short direction. It has the extension parts 36B and 36B. 36 A of 1st extension parts and the 2nd extension part 36B are connected by the connection part 36C, and the extension direction of each extension part is each 36 A of 1st extension parts and the 2nd extension part 36B. Four (plural) cuts 37A are formed along the direction intersecting with.

  Thus, by providing the first extending portion 36 </ b> A and the second extending portion 36 </ b> B that intersect each other inside the frame-shaped portion 35, the vehicle seat member 10 can be reinforced. Further, by forming a cut 37A in both the first extension portion 36A and the second extension portion 36B, it is possible to suppress thermal deformation such as bending of the first extension portion 36A and the second extension portion 36B. Can do. Furthermore, the deformation of the first extending portion 36A and the second extending portion 36B, which is caused by the thermal shrinkage of the foamed resin molded body 30 after the molding, can be suppressed.

  In the embodiment shown in FIG. 10, the notches 37A are formed in both the first extending portion 36A and the second extending portion 36B. For example, as shown in FIG. 11, the second extending in the short direction is used. A notch groove 37B may be formed in the extending portion 36B instead of the notch 37A. Accordingly, the first extending portion 36A that is more easily thermally deformed than the second extending portion 36B can more reliably suppress the thermal deformation by the cut 37A. On the other hand, by forming the notched groove 37B in the second extending portion 36B that is hard to be thermally deformed compared to the first extending portion 36A, it is possible to suppress the heat deformation while ensuring the strength.

  In the present embodiment shown in FIG. 10, the frame member 20 continuously circulates along the contour S of the vehicle seat member 10, but the frame member 20 extends along the contour S of the vehicle seat member 10. It suffices if it is arranged at least in part. Accordingly, as shown in FIG. 12, the second skeleton portion 22 is not connected to the pedestal portions 23 and 23, but is disposed only along the rear edge portion sB, and a notch 37A is formed only in the first extending portion 36A. May be. In this case, a cut 37A may be provided in the first extending portion 36A extending in the longitudinal direction.

  Further, as shown in FIG. 13, the frame material having the second frame portion 22 (continuous portion) in which the opposing portions 22 a and 22 a facing each other with the space inside the frame-like portion 35 interposed therebetween are continuous. 20 may be used.

  As mentioned above, although some embodiment of this invention was explained in full detail, this invention is not limited to the said embodiment, In the range which does not deviate from the mind of this invention described in the claim, Various design changes can be made.

1: vehicle seat, 7: molding die, 10: vehicle seat member, 20: frame material, 21: first frame portion, 22: second frame portion (continuous portion), 22a: facing portion, 30: foamed resin Molded body, 35: frame-like portion, 36: extending portion, 36a: dividing portion, 36A: first extending portion, 36B: second extending portion, 37a: groove bottom portion, 37b: groove opening portion, 37A: notch 37B: Notch groove, 37C: Cut, L: Extension direction, S: Contour

Claims (10)

A method for manufacturing a vehicle seat member comprising a frame material and a foamed resin molded body in which the frame material is embedded,
An arrangement step of arranging the frame material in a mold so that the frame material is arranged along an outline of the vehicle seat member in a plan view of the vehicle seat member;
In the mold, the frame material is embedded and the contour of the vehicle seat member is formed, and the frame-shaped portion extends inward from the frame-shaped portion so as to extend inside the frame-shaped portion. A molding step for molding a foamed resin molded body including the extending portion,
During the forming step, a notch groove, a cut, or a notch that divides the extending portion is formed in the extending portion along a direction intersecting the extending direction in which the extending portion extends. A method for manufacturing a vehicle seat member. The frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous,
The method for manufacturing a vehicle seat member according to claim 1, wherein in the molding step, the extending portion is molded so as to extend between the opposing portions. The outline of the vehicle seat member in the plan view is a shape having a short direction and a long direction,
In the forming step, the extending portion is formed so as to include at least a first extending portion extending along the longitudinal direction across the opposing portion of the frame-shaped portion, and the notch groove The method of manufacturing a vehicle seat member according to claim 1, wherein the cut or the cut is formed in the first extending portion.   The method for manufacturing a vehicle seat member according to any one of claims 1 to 3, wherein the cutout groove is formed so as to expand from the groove bottom toward the groove opening.   The method for manufacturing a vehicle seat member according to any one of claims 1 to 4, wherein the frame member is circulated along an outline of the vehicle seat member. A vehicle seat member comprising a frame material and a foamed resin molded body in which the frame material is embedded,
The frame material is arranged along an outline of the vehicle seat member in a plan view of the vehicle seat member,
The foamed resin molded body includes a frame-shaped portion that embeds the frame material and forms an outline of the vehicle seat member, and an inner side from the frame-shaped portion so as to pass the frame-shaped portion inside the frame-shaped portion. And an extending portion extending to
The extension part is formed with a notch groove, a cut, or a cut that divides the extension part along a direction intersecting the extension direction in which the extension part extends. A vehicle seat member.   The frame material has a continuous portion in which opposed portions facing each other across a space inside the frame-shaped portion are continuous, and the extending portion is formed to extend between the opposed portions. The vehicle seat member according to claim 6, wherein the vehicle seat member is formed. The outline of the vehicle seat member in the plan view is a shape having a short direction and a long direction,
The extension part includes a first extension part along the longitudinal direction over the opposing part of the frame-like part,
The vehicle seat member according to claim 6 or 7, wherein the cutout groove, the cut, or the cut is formed in the first extending portion.   The vehicle seat member according to any one of claims 6 to 8, wherein the cutout groove is formed so as to expand from the groove bottom toward the groove opening.   The vehicle frame member according to any one of claims 6 to 9, wherein the frame member circulates along an outline of the vehicle seat member.

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