JP2018029844A - 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 production method of a vehicle seat member 10 comprising a frame material 20 and a foam resin molding body 30 comprises: an arrangement step for arranging the frame material 20 in a molding tool 7 so that the frame material 20 is arranged along a contour S of the vehicle seat member 10; and a molding step for molding in the molding tool 7, the foam resin molding body 30 comprising a frame-shaped part 35 in which at least a part of 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. In the molding step, the foam resin molding body 30 is molded so that the extension part 36 includes a foam resin whose flexure maximum point stress is larger than that of a foam resin which is included in a non-connection part 35'' other than a connection part 35' connected to the extension part 36 in the frame-shaped part 35.SELECTED DRAWING: Figure 2

Description

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

  As a vehicle seat 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).

  Patent Document 3 discloses a method for manufacturing a vehicle seat member in which a latch for fixing to a vehicle and a connecting member that connects the latch are used as a frame material, and this is embedded in a foamed particle molded body and integrally molded. . 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, it is described that an incision extending from the pillar portion to the outside in the longitudinal direction is formed outside the longitudinal direction of the vehicle seat member in the foamed particle molded body portion in which the pillar portion of the latch is embedded. Has been.

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.

In order to solve the above-mentioned problem, a method for manufacturing a vehicle seat member according to the present invention disclosed in this specification includes:
A method of manufacturing a vehicle seat member comprising a frame material and a foamed resin molded body in which at least a part of 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;
A frame-shaped portion that embeds at least a part of the frame material and forms an outline of the vehicle seat member in the mold, and the frame-shaped portion so as to pass the frame-shaped portion inside the frame-shaped portion A molding step of molding a foamed resin molded body including an extending portion extending inward from
Including
In the molding step, the extending part includes a foamed resin having a larger bending maximum point stress than a foamed resin included in a non-connecting part other than a connecting part connected to the extending part in the frame-shaped part. The foamed resin molded body is molded.

  In a method for manufacturing a vehicle seat member, a frame-shaped portion in which at least a part of a frame material is embedded in a foamed resin molded body, and an extended portion that extends inside the frame-shaped portion and does not have a frame material And the apparent heat shrinkage amount 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, by extending the foamed resin molded body such that the extending portion includes a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connected portion of the frame-shaped portion, The rigidity of the extending portion is made higher than that of the non-connection portion of the frame-shaped portion, and the deformation of the extending portion due to the stress acting on the extending portion is suppressed. Thereby, even if the foamed resin molded body including the frame-like portion and the extending portion is thermally contracted during or after molding, deformation of the extending portion can be suppressed. Moreover, the bending maximum point stress of the foamed resin can be easily controlled by means such as changing the expansion ratio. For this reason, a vehicle seat member with high dimensional accuracy can be manufactured easily. In addition, as another means for suppressing the deformation of the extending portion, increasing the maximum bending point stress of the entire foamed resin molded body including the extending portion and the frame-shaped portion (referred to as “other means 1”). ), Increasing the thickness of the extension (referred to as “other means 2”), and the like. However, according to the said other means 1, there exists a possibility of the weight increase of the whole foamed resin molding, an increase in cost, etc. According to the said other means 2, since the design of an extension part is restrict | limited, a use may be restrict | limited. In the present invention, since these possibilities are low, it is remarkably advantageous as compared with the other means 1 and 2.

In a preferred aspect of the vehicle seat member manufacturing method according to the present invention,
The frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous,
In the molding step, the foamed resin molded body is molded such that the extending portion extends between the opposing portions.
When the frame material has the continuous portion, both sides of the extending portion are restrained by the portion of the frame-like portion that embeds the continuous portion. In this structure, the extended portion is particularly easily deformed by heat shrinkage. In this aspect of the present invention, in the molding process, the foamed resin is so formed that the extended portion extends between the opposing portions of the continuous structure. By forming the molded body, the deformation of the extending portion can be suppressed.

In a further preferred aspect of the method for manufacturing a vehicle seat member according to the present invention,
The outline of the vehicle seat member in the plan view is a shape having a short direction and a long direction,
In the molding step, the extending portion includes a first extending portion extending along at least the longitudinal direction over the opposing portion of the frame-shaped portion, and the first extending portion is The foamed resin molded body is molded so as to include a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion of the frame-shaped portion.
The first extending portion formed along the longitudinal direction is easily deformed by heat shrinkage. In this aspect, the first extending portion is bent to the maximum than the foamed resin included in the non-connecting portion of the frame-shaped portion. By forming the foamed resin molded body so as to include a foamed resin having a large point stress, deformation of the first extending portion can be suppressed.
In a further preferred aspect of the method for manufacturing a vehicle seat member according to the present invention,
In the arranging step, at least a part of the frame material 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. Moreover, when the frame material is circulated along the contour of the vehicle seat member, both sides of the extended portion are constrained and easily deformed by heat shrinkage. According to this aspect, the extended portion is the frame-shaped portion. By forming a foamed resin molded body so as to include a foamed resin that has a maximum bending point stress greater than that of the foamed resin, it is possible to increase the rigidity of the extended part, and the extended part due to the stress acting on the extended part Can be prevented from being deformed.

The present invention further relates to a vehicle seat member.
The vehicle seat member according to the present invention comprises:
A vehicle seat member comprising a frame material and a foamed resin molded body in which at least a part of 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-like portion that embeds at least a part of the frame material and forms an outline of the vehicle seat member, and the frame-like portion that extends over the frame-like portion inside the frame-like portion. An extending portion extending inward from the shape portion,
In the foamed resin molded body, the extending portion includes a foamed resin having a bending maximum point stress larger than a foamed resin included in a non-connecting portion other than a connecting portion connected to the extending portion in the frame-shaped portion. It is characterized by.

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 Thus, the apparent thermal expansion amount (thermal contraction amount) differs from that of the extended portion where no frame material is present. 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, the extending portion extending inside the frame-shaped portion includes a foamed resin having a bending maximum point stress larger than the foamed resin included in the non-connecting portion of the frame-shaped portion. It is possible to increase the rigidity of the extending portion as compared with the frame-shaped portion, suppress deformation of the extending portion, and ensure the dimensional accuracy of the vehicle seat member. As other means for suppressing deformation of the extending portion, the other means 1, 2 and the like can be considered. However, according to the said other means 1, there exists a possibility of the weight increase of the whole foamed resin molding, an increase in cost, etc. According to the said other means 2, since the design of an extension part is restrict | limited, a use may be restrict | limited. In the present invention, since these possibilities are low, it is remarkably advantageous as compared with the other means 1 and 2.

In a more preferred aspect of the vehicle seat member according to the present invention,
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. Is done.
When the frame material has the continuous portion, both sides of the extending portion are restrained by the portion of the frame-like portion that embeds the continuous portion. When heat is applied to the vehicle seat member having this structure (or when the heat input is dissipated), the extended portion is particularly easily deformed by heat shrinkage. In this aspect of the present invention, the extended portion is Since the foamed resin contains a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion of the frame-like portion, the extending portion is difficult to deform.

In a more preferred aspect of the vehicle seat member according to the present invention,
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 first extending portion includes a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion of the frame-shaped portion.
The first extending portion formed along the longitudinal direction is easily deformed by heat shrinkage. According to this aspect, the first extending portion is more than the foamed resin included in the non-connecting portion of the frame-shaped portion. Since the foamed resin having a large bending maximum point stress is included, the first extending portion is hardly deformed.

In a more preferred aspect of the vehicle seat member according to the present invention,
The frame material circulates along the contour of the vehicle seat member.
According to this aspect, since the frame material circulates along the contour of the vehicle seat member, the strength of the vehicle seat member is high. Moreover, when the frame material is circulated along the contour of the vehicle seat member, both sides of the extended portion are constrained and easily deformed by heat shrinkage. According to this aspect, the extended portion is the frame-shaped portion. Since the foamed resin having a bending maximum point stress larger than that of the contained foamed resin is included, the extension portion has high rigidity, and deformation of the extension portion is 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 heat input is dissipated. Can do.

It is a typical perspective view for demonstrating the structure of a frame material which looked at the vehicle seat member which concerns on 1st Embodiment of this invention from the downward direction. It is a typical perspective view for demonstrating the structure of the foaming resin molding which looked at the vehicle seat member which concerns on 1st Embodiment of this invention from the downward direction. It is a left view of the vehicle seat member which concerns on 1st Embodiment of this invention. It is a top view when the seat member for vehicles concerning a 1st embodiment of the present invention is seen from the upper surface. It is typical sectional drawing in the position corresponding to the II sectional view taken on the line in FIG. 4 for demonstrating the manufacturing method of the vehicle seat member which concerns on 1st Embodiment of this invention. (A) is typical sectional drawing of the state which filled the preforming resin particle in the shaping | molding die. (B) is a schematic cross-sectional view of a state in which pre-foamed resin particles are foamed from the state shown in (A) to form a foamed resin molded article. (C) is typical sectional drawing which shows the state which demolded the foamed resin molding from the state shown to (B). It is typical sectional drawing in the position corresponding to the II-II arrow directional cross-sectional view shown in FIG. 4 for demonstrating the manufacturing method of the vehicle seat member which concerns on 1st Embodiment of this invention. (A) is typical sectional drawing of the state which filled the preforming resin particle in the shaping | molding die. (B) is a schematic cross-sectional view of a state in which pre-foamed resin particles are foamed from the state shown in (A) to form a foamed resin molded article. (C) is typical sectional drawing which shows the state which demolded the foamed resin molding from the state shown to (B). It is typical sectional drawing for demonstrating the manufacturing method of the vehicle seat member used as a comparative example. (A) is typical sectional drawing of the state which expanded the pre-expanded particle and shape | molded the foaming resin molding. (B) is the typical sectional view showing the state where the foamed resin molding was removed from the mold from the state shown in (A). It is a typical perspective view for demonstrating the structure of a frame material which looked at the vehicle seat member which concerns on 2nd Embodiment of this invention from the downward direction. It is a typical perspective view for demonstrating the structure of the foaming resin molding which looked at the vehicle seat member which concerns on 2nd Embodiment of this invention from the downward direction.

  In the following description, first, materials for preparing the foamed resin molded body according to the present invention will be described, and then several embodiments of the vehicle seat member and the vehicle seat according to the present invention will be described with reference to the drawings. While explaining. However, the scope of the present invention is not limited to individual embodiments.

<Material for preparing foamed resin molding>
In the present invention, the “foamed resin molded article” refers to filling pre-foamed resin particles obtained by pre-foaming expandable resin particles containing a resin and a foaming agent in a mold, and placing the pre-foamed resin particles in the mold. This refers to a molded product that is re-foamed and foam-molded in the mold.
In the present invention, a material constituting each part of the foamed resin molded body is referred to as “foamed resin”.
The “resin”, “foaming agent”, “foamable resin particle”, and “pre-foamed resin particle” will be specifically described.

(resin)
Although it does not specifically limit as resin, Usually, a thermoplastic resin is used, For example, the composite resin containing polystyrene resin and polyolefin resin, polystyrene resin, polyolefin resin, polyester resin etc. can be used.
The expandable resin particles are obtained by impregnating resin particles with a foaming agent. The foamable resin particles may be impregnated with the foaming agent simultaneously with the polymerization of the resin, or may be impregnated with the foaming agent after the polymerization of the resin.
Below, the resin particle which can be used suitably for this invention and the expandable resin particle which impregnated the resin particle with the foaming agent are explained in full detail.

(Composite resin particles containing polystyrene resin and polyolefin resin)
The composite resin particles contain a polyolefin resin and a polystyrene resin.
The shape of the composite resin particles is preferably, for example, a true spherical shape, an elliptical spherical shape (egg shape), or a cylindrical shape.
Moreover, although there is no special restriction | limiting in an average particle diameter, 0.3-7 mm can be illustrated.
Further, the ratio (L / D) between the maximum diameter L and the minimum diameter D of the composite resin particles is not particularly limited, but is preferably 1 to 1.6.

(1) Polyolefin resin Examples of the polyolefin resin include resins containing units derived from olefin monomers having 2 to 10 carbon atoms such as polypropylene and polyethylene. The polyolefin-based resin may be a homopolymer of an olefin monomer or a copolymer with another monomer that can be copolymerized with the olefin monomer. Furthermore, the polyolefin resin may be cross-linked. Examples of the copolymer include a copolymer (EVA) of vinyl acetate and ethylene. As the polyolefin resin, for example, a resin having an average mass molecular weight of 180 to 500,000 can be used.

(2) Polystyrene resin Examples of the polystyrene resin include resins derived from styrene monomers such as styrene and substituted styrene (substituents include lower alkyl, halogen atoms (particularly chlorine atoms) and the like). Examples of the substituted styrene include α-methyl styrene, p-methyl styrene, t-butyl styrene, ethyl styrene, i-propyl styrene, dimethyl styrene, vinyl toluene, chlorostyrene bromostyrene, and the like. Furthermore, the polystyrene resin may be a copolymer of a styrene monomer and another monomer copolymerizable with the styrene monomer. Examples of other monomers include acrylonitrile, (meth) acrylic acid alkyl ester (alkyl moiety having about 1 to 8 carbon atoms), divinylbenzene, ethylene glycol mono- or di (meth) acrylic acid ester, maleic anhydride, N -Phenylmaleimide and the like.
When using another monomer, it is preferable to use it in 30 mass parts or less with respect to 100 mass parts of styrene-type monomers.
The polystyrene resin is more preferably a resin derived from styrene only.

(3) Content of polyolefin-type resin and polystyrene-type resin Content of polystyrene-type resin is 120-400 mass parts with respect to 100 mass parts of polyolefin-type resin, Preferably it is 150-250 mass parts.

(4) Other additives The composite resin particles may contain other additives. Other additives include nucleating agents, coloring agents, flame retardants, flame retardant aids, antioxidants, ultraviolet absorbers, scaly silicates, and the like.

(5) Production method of composite resin particles The composite resin particles may be produced by any method as long as the polyolefin resin and the polystyrene resin can be contained in the particles. For example, a method of kneading both resins in an extruder and cutting the kneaded product, a method of impregnating a seed particle containing a polyolefin resin with an styrene monomer in an aqueous medium, and then polymerizing the monomer, etc. It is done. Among these, the latter method is preferable from the viewpoint of more uniformly mixing both resins and obtaining particles having a more spherical shape. Here, the composite resin particles obtained by the latter method are also referred to as polyolefin-modified polystyrene resin particles or simply modified resin particles.

(6) Commercially available composite resin particles Commercially available products can be purchased and used as composite resin particles containing a polystyrene resin and a polyolefin resin. Examples of commercially available composite resin particles containing a polystyrene resin and a polyolefin resin include PIOCERAN (registered trademark): OP-30EU, OP-30ELV manufactured by Sekisui Plastics Co., Ltd.

(Polystyrene resin particles)
(1) Polystyrene resin The polystyrene resin constituting the polystyrene resin particles is not particularly limited. For example, styrene, α-methylstyrene, vinyltoluene, chlorostyrene, ethylstyrene, i-propylstyrene, dimethylstyrene, A homopolymer of a styrene monomer such as bromostyrene or a copolymer of two or more of these monomers may be mentioned, and a polystyrene resin containing 50% by mass or more of a styrene component is preferable, and polystyrene is more preferable.

  The polystyrene resin may be a copolymer of the styrene monomer as a main component and a vinyl monomer copolymerizable with the styrene monomer. Examples of such vinyl monomers include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, alkyl (meth) acrylates such as cetyl (meth) acrylate, (meth) acrylonitrile, dimethyl maleate, In addition to dimethyl fumarate, diethyl fumarate, and ethyl fumarate, bifunctional monomers such as divinylbenzene and alkylene glycol dimethacrylate are exemplified.

In addition, the polystyrene resin may contain other additives as mentioned in (4) of (Composite resin particles containing polystyrene resin and polyolefin resin).
The shape of the polystyrene-based resin particles used in the present invention is not particularly limited, but a spherical shape is preferable, and the particle diameter is from the viewpoint of easy filling of the polystyrene-based resin pre-expanded particles described later into a mold. The thickness is 3 to 2.0 mm, preferably 0.3 to 1.4 mm. Further, when the shape is a columnar shape, the volume corresponding to the preferable particle diameter is preferable. Furthermore, the styrene conversion weight average molecular weight (Mw) of the polystyrene resin can be in the range of 120,000 to 600,000.

(2) Method for Producing Polystyrene Resin Particles There is no particular limitation on the method for producing the polystyrene resin particles used as the material of the expandable polystyrene resin particles. For example, the polystyrene resin is supplied to an extruder and melt-kneaded and extruded. A method of producing polystyrene resin particles by extruding into a strand form from a machine and cooling and then cutting into a predetermined length (strand cut method), and simultaneously extruding into water from a hole in a die attached to the tip of the extruder. And cooling to produce polystyrene resin particles (in-water hot-cut method). Further, after the scaly silicate or metal oxide is dispersed in the resin in the extruder, polystyrene resin particles may be cut by predetermined lengths. Further, the polystyrene resin particles are obtained by seed polymerization by impregnating a polystyrene resin seed particle with a styrene monomer in a suspension in water using the obtained polystyrene resin particle as a seed particle. You may employ | adopt the method of adding a foaming agent to the polystyrene resin particle manufactured and produced subsequently.

(3) Commercially available polystyrene resin particles Commercially available products can be purchased and used as polystyrene resin particles. Examples of commercially available polystyrene resin particles include Sekisui Kasei Kogyo Co., Ltd.'s eslen beads: FDK-40LV, ESDK, and the like.

(Other resin particles)
As for the other resin particles, the composite resin particles containing the polystyrene resin and the polyolefin resin described in detail above, or the resin particles having the same shape as the polystyrene resin particles can be used. A thing can be contained suitably.

  Examples of other resin particles include polyolefin resin particles and polyester resin particles. Examples of the polyolefin resin particles include the polyolefin resin particles described above as components contained in composite resin particles including a polystyrene resin and a polyolefin resin. An example of the polyester resin constituting the polyester resin particles is polyethylene terephthalate.

As a method for producing particles containing these other resins, a general method is used in the same manner as the composite resin particles or polystyrene resin particles containing the polystyrene resin and the polyolefin resin described in detail above.
You may purchase and use a commercial item also about the particle | grains containing other resin.

(Expandable resin particles)
It does not specifically limit as a foaming agent contained in an expandable resin particle, All can use a well-known thing. In particular, a gaseous or liquid organic compound having a boiling point below the softening point of the resin used and normal pressure is suitable. Examples thereof include hydrocarbons such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane, cyclopentane, cyclopentadiene, n-hexane, and petroleum ether. These foaming agents may be used alone or in combination of two or more. As the blowing agent, carbon hydrogen is preferable, and propane, n-butane, isobutane, n-pentane, isopentane and the like are more preferable.

  Although content of the foaming agent in an expandable resin particle is not specifically limited, Typically, it is 5-25 mass parts with respect to 100 mass parts of expandable resin particles. The content of the foaming agent in the expandable resin particles was measured after being left in a thermostatic chamber at 13 ° C. for 5 days immediately after production.

(Method for producing expandable resin particles)
The impregnation of the foaming agent into the resin particles may be performed on the particles after polymerization of the resin, or may be performed on particles in the middle of polymerization. Impregnation during the polymerization can be performed by a method of impregnation in an aqueous medium (wet impregnation method). The impregnation after polymerization can be carried out by a wet impregnation method or a method of impregnation in the absence of a medium (dry impregnation method). Moreover, it is preferable to perform the impregnation in the middle of the polymerization usually in the latter stage of the polymerization. The late stage of polymerization is preferably after 70% by mass of the constituent monomers have been polymerized. It is also possible to impregnate the foaming agent following the polymerization after 99% by mass of the constituent monomers have been polymerized.
The impregnation temperature of the foaming agent can be 50 to 140 ° C.

  The impregnation with the foaming agent may be performed in the presence of a foaming aid. Examples of the foaming aid include solvents such as toluene, xylene, ethylbenzene, and cyclohexane, and plasticizers (high-boiling solvents) such as diisobutyl adipate, diacetylated monolaurate, and coconut oil. The addition amount of the foaming aid is preferably 0.2 to 2.5 parts by mass with respect to 100 parts by mass of the resin particles.

  If necessary, a surface treatment agent (for example, a binding inhibitor, a fusion accelerator, an antistatic agent, a spreading agent, etc.) may be added to the system during impregnation with the foaming agent. As addition amount (total value) of these surface treating agents, 0.01-2 mass parts can be illustrated with respect to 100 mass parts of resin particles.

(Pre-foamed resin particles)
The expandable resin particles are expanded (pre-expanded) with water vapor or the like in a foaming machine (preliminary foaming machine) to be pre-expanded resin particles having a large number of small holes (also simply referred to as expanded resin particles).
The bulk multiple of the pre-expanded resin particles can be adjusted according to the foam multiple of the target foam resin.

(In-mold foam molding)
In-mold foam molding conditions and the like will be described in the following description of the first embodiment.

<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. 4, 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. 4, 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. 3, the vehicle seat member 10 of the present embodiment is an upper seat member such as a cushion material as appropriate from the upper surface 11 (upper surface 31) side of the vehicle seat member 10 (foamed resin molded body 30). 50 can be laminated and used as 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.

2. About Frame Material 20 As shown in FIGS. 1 to 4, the frame material 20 is embedded to give the foamed resin molded body 30 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 framework portions 21 and 22 that extend into the foamed resin molded body 30 along the contour S in plan view of the vehicle seat member 10, and first and second framework portions. A pair of pedestal portions 23 and 23 connected to the end portions of 21 and 22 are provided. The second frame portion 22 has a structure in which a pair of opposed portions 22a and 22a facing each other is continuous. In the present specification, the second frame portion 22 may be referred to as a “continuous portion” of the frame material 20 in some cases. .

  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 member 20 is disposed in the vicinity of a part of the center of the front edge portion sF, and the second frame portion 22 includes a part on both sides of the front edge portion sF and a right side. It is disposed in the vicinity of the edge portion sR, the left 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 way, the first and second frame portions 21 and 22 of the frame member 20 continuously circulate along the contour S of the vehicle seat member 10 together with the pair of pedestal portions 23 and 23 that connect them. ing. In the present embodiment, the portion including the first and second frame portions 21 and 22 of the frame material 20 continuously circulates along the contour S of the vehicle seat member 10. The 20 first and second frame portions 21 and 22 may intermittently circulate along the contour S of the vehicle seat member 10. 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 constituting 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 center of the portion 22b along the rear edge portion sB in the second framework 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.

3. About Foamed Resin Molded Body 30 As shown in FIGS. 1 and 2, the foamed resin molded body 30 is an in-mold foamed resin molded body of foamed resin. The foamed resin molded body 30 is obtained by filling pre-foamed resin particles obtained by pre-foaming expandable resin particles containing a resin and a foaming agent in a mold, and re-foaming the pre-foamed resin particles in the mold. Specific examples of the resin, the foaming agent, the expandable resin particles, and the pre-expanded resin particles are as described above.

  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 is formed integrally with the front portion 35a located in front of the seat and the front portion 35a in a state in which the vehicle seat member 10 is attached, and is located on the left and right sides of the seat. A pair of side portions 35c, 35c extending rearward from both ends 35a and inclined in the vicinity of the rear end and the side portions 35c, 35c are formed integrally with the rear ends of the pair of side portions 35c, 35c. And a rear portion 35b for connecting the two. When the vehicle seat member 10 is incorporated into the vehicle, the front portion 35a of the frame-shaped portion 35 supports the upper leg portion of the occupant and the rear portion 35b supports the buttocks of the occupant.

  Specifically, as shown in FIG. 3, the upper surface 31 of the foamed resin molded body 30 is a curved surface that is recessed downward, and holds the occupant's upper thigh and buttocks via the upper sheet member 50. It is formed as follows. 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. In the present invention, a portion of the extending portion that extends along a predetermined direction is referred to as an “extending portion”. The extension part may consist of only one extension part, or may consist of a plurality of extension parts. In the present embodiment, the extending portion 36 includes a first extending portion 36A extending in the longitudinal direction and a second extending portion 36B extending in the short direction. 36 A of 1st extension parts and the 2nd extension part 36B are connected by the connection part 36C. In the present embodiment, the extending portion 36 is composed of a plurality of extending portions 36A and 36B, but is not limited thereto, and may be composed of only one extending portion. For example, the extending part 36 may be composed of only the first extending part 36A, or may be composed of only the second extending part 36B. When the extension part 36 includes a plurality of extension parts extending so as to extend over the frame-like part 35, each of the plurality of extension parts can be provided along an arbitrary direction.

  Of the frame-shaped portion 35, a portion connected to the extending portion 36 is a connecting portion 35 ', and a portion other than the connecting portion 35' is a non-connecting portion 35 ". Specifically, the connecting portion 35 ′ of the frame-like portion 35 is connected to and supported by the ends of the extending portions 36 </ b> A and 36 </ b> B of the extending portion 36.

  In the present embodiment, the frame member 20 has a second frame portion 22 (continuous portion) in which opposed portions 22a and 22a that face each other across a space inside the frame-shaped portion 35 are continuous. A first extending portion 36A of the extending portion 36 is formed so as to extend between the facing portions 22a and 22a.

  In the foamed resin molded body 30, the extending portion 36 is a portion that reinforces and holds the shape of the vehicle seat member 10. By forming the extending portion 36 in the space inside the frame-shaped portion 35 in the foamed resin molded body 30, a lightening portion 38 a is formed between the frame-shaped portion 35 and the extending portion 36. The lightening portion 38a reduces the weight of the foamed resin molded body 30 and other members constituting the vehicle seat (for example, a cushion material that is more easily elastically deformed than the foamed resin molded body 30, a member of a console box, etc.). It is provided for the purpose of accommodation. In the illustrated embodiment, six portions 38a are formed on the foamed resin molded body 30, but the number of the portion 38a is not limited.

  The extending portion 36 of the foamed resin molded body 30 includes a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion 35 ″ of the frame-shaped portion 35. 2 to 4, the foamed resin having a large bending maximum point stress is shown in a dark color, and the foaming resin having a small bending maximum point stress is shown in a light color. More specifically, the extending direction L in which the first extending portion 36A of the extending portion 36 extends coincides with the longitudinal direction of the vehicle seat member 10, and the entire first extending portion 36A. However, it includes a foamed resin having a bending maximum point stress larger than that of the foamed resin forming the non-connecting portion 35 ″ of the frame-shaped portion 35. When a plurality of extending portions are present in the extending portion 36 as in the illustrated embodiment, at least one extending portion is more than the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35. It is only necessary to include a foamed resin having a large bending maximum point stress. Preferably, the whole of the at least one extending portion has a bending maximum point higher than that of the foamed resin included in the non-connecting portion 35 '' of the frame-like portion 35. It is formed of a foamed resin having a large stress.

  The rigidity of each part of the foamed resin molded body 30 is higher as the bending maximum point stress of the foamed resin included in the part is larger if the same shape has the same dimensions. In the present embodiment, the foamed resin molded body 30 is molded such that the extending portion 36 includes a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35. Thus, the rigidity of the extending portion 36 can be selectively increased.

  In the present invention, the extended portion 36 is a foamed resin (hereinafter sometimes referred to as “predetermined foamed resin”) having a maximum bending point stress greater than that of the foamed resin included in the non-connecting portion 35 ″ of the frame-like portion 35. “Contains” means that the extension part 36 contains a predetermined foamed resin to such an extent that sufficient rigidity is imparted to at least one extension part. The foamed resin may be further included. Preferably, at least one extending portion of the extending portion 36 includes a predetermined foamed resin, and more preferably, the at least one extending portion is formed of a predetermined foamed resin.

In the present invention, the bending maximum point stress (kPa) of the foamed resin is measured in accordance with a bending test specified by ASTM D790 Procedure A. The conditions for the bending test are specifically as follows.
Testing device: Tensilon universal testing machine UCT-10T (manufactured by Orientec Co., Ltd.)
Test piece: 79.2W × 380L × 19.8T thickness (mm) (no skin)
Number of tests: 5
Test speed: 8.4 mm / min
Distance between fulcrums: 316.7 (mm)
Maximum deflection: 64mm
Tip jig: pedestal wedge 5R, pressure wedge 5R
Test piece condition adjustment / test environment: Temperature: 23 ± 2 ° C., Relative humidity (RH): 50 ± 10%, 24 hours or more

  In the present invention, the bending maximum point stress of the foamed resin contained in the non-connected portion of the frame-shaped part of the foamed resin molded body is not particularly limited, but is typically 10 to 600 kPa, typically, for example. The range is from 100 to 500 kPa. On the other hand, the bending maximum point stress measured under the above conditions of the foamed resin contained in at least a part of the extending part of the foamed resin molded body is higher than that of the foamed resin contained in the non-connected part of the frame-shaped part, For example, it is 1.2 to 5 times, and typically 1.5 to 4 times the bending maximum point stress of the foamed resin contained in the non-connection portion of the frame-like portion. The absolute value of the bending maximum point stress measured under the above conditions of the foamed resin contained in at least a part of the extended portion of the foamed resin molded body is, for example, 150 to 2,000 kPa, typically 250 to 1. , 200 kPa. In the foamed resin molded body 30, the resin in the foamed resin constituting each part can be selected from the above types of resins, and does not have to be formed of the same series of resins. However, it is preferable that the entire foamed resin molded body 30 is composed of a resin foam of the same system because each part of the foamed resin molded body 30 is firmly connected. When the entire foamed resin molded body 30 is composed of the same resin foam except that the bending maximum point stress is different, each part of the foamed resin molded body 30 is preferably connected more firmly. .

  The bending maximum point stress of the foamed resin is preferably controlled by controlling the expansion ratio of the foamed resin. In the foamed resin composed of the same resin material, the bending maximum point stress is larger as the expansion ratio is smaller. The specific gravity of the foamed resin is larger as the foaming factor is smaller. Therefore, in the present invention, in the aspect in which the bending maximum point stress is increased by decreasing the expansion ratio of the foamed resin, the extending portion is bent with a smaller expansion ratio than the expanded resin included in the non-connected portion of the frame-shaped portion. By molding the foamed resin molded body so as to include a foamed resin having a large maximum point stress, it is possible to suppress an increase in the weight of the foamed resin molded body while selectively increasing the rigidity of the extending portion.

In the aspect in which the bending maximum point stress of the foamed resin is controlled by controlling the expansion factor, the specific range of the expansion factor is not particularly limited, but the non-connection portion 35 '' of the frame-shaped portion 35 is, for example, 21 times to The expanded portion 36 includes a foamed resin having a foaming ratio of, for example, 2.5 times to 20 times or 2.5 times to 10 times. A foamed resin that satisfies these ranges of the foaming ratio and that the extending part 36 includes a foamed resin having a smaller foaming factor than the foaming multiple of the foamed resin contained in the non-connecting part 35 ″ of the frame-like part 35. It is preferable to mold the molded body 30.
Here, the expansion ratio of the foamed resin contained in each part of the foamed resin molded body 30 can be obtained by the following procedure.

Each part of the foamed resin molded body 30 (after being molded and dried at 40 ° C. for 20 hours or more) (extension parts 36A and 36B of the extension part 36, unconnected parts 35 ″ of the frame part 35, frame shape The weight (c) and the volume (d) of the test piece (eg, 50 mm × 100 mm × 10 mm rectangular parallelepiped piece) cut out from the portion 35 ′ of the portion 35 where the expansion ratio is to be measured are significant figures. It measures so that it may become 3 digits or more, and calculates | requires the density (g / cm < ³ >) of a foaming molding by Formula (c) / (d). The reciprocal of the density, that is, the formula (d) / (c) is defined as the expansion factor.

  Further, in addition to the extending portion 36, the connecting portion 35 ′ of the frame-like portion 35 connected to the extending portion 36 has a bending maximum point stress higher than the foamed resin included in the non-connecting portion 35 ″ of the frame-like portion 35. It is preferable to contain a foamed resin having a large size. When there are a plurality of extending portions 36A and 36B in the extending portion 36, at least one of the extending portions 36A and 36B (for example, 36A) and the frame-like portion 35 connected to the at least one extending portion It is preferable that the connecting portion 35 ′ includes a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connected portion 35 ″ of the frame-like portion 35.

  Here, tentatively, the first and second frame portions 21 and 22 of the frame material 20 are embedded in the frame-shaped portion 35 of the foamed resin molded body 30, and the extending portion 36 is a non-connection portion 35 of the frame-shaped portion 35. When the extension portion 36 and / or the frame-like portion 35 is not reinforced by other means, it is inserted into the vehicle seat member 10. When heated (or when the input heat is dissipated), the frame-shaped portion 35 in a state in which the first and second frame portions 21 and 22 of the frame material 20 are 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 first extending portion 36A formed along the longitudinal direction in the extending portion 36.

  In the present embodiment, the first extending portion 36 </ b> A extending along the longitudinal direction among the extending portions 36 extending inside the frame-shaped portion 35 and the first extending portion 36 </ b> A among the frame-shaped portions 35. The extending portion 36 is reinforced by forming the connecting portion 35 ′ to be connected to the foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion 35 ″ of the frame-like portion 35. Thereby, even if the extending part 36 is thermally expanded or contracted, deformation of the extending part 36 due to thermal stress can be suppressed, and the dimensional accuracy of the vehicle seat member 10 can be ensured. According to the present embodiment, the first extending portion 36A of the extending portion 36 and the connecting portion 35 'connected to the first extending portion 36A of the frame-like portion 35 are selectively reinforced, and the frame-like portion Since the 35 non-connecting portions 35 '' can be made of a normal foamed resin, the overall weight increase and cost increase of the foamed resin molded body 10 are small. Moreover, according to this embodiment, since reinforcement, such as forming the 1st extension part 36A of the extension part 36 thickly, is unnecessary, possibility that a design and a use will be restrict | limited is low.

  In particular, in the present embodiment, the second frame portion 22 having a structure in which a pair of opposed portions 22a and 22a facing each other is continuously embedded in the frame-shaped portion 35, and the first extending portion 36A of the extending portion 36 is provided. Is formed so as to extend between the opposing portions 22a, 22a. In this configuration, since both sides of the first extension portion 36A of the extension portion 36 are constrained, the first extension portion 36A is assumed to have the same bending maximum point stress as the non-connection portion 35 ″ of the frame-like portion 35. In the case where the extending portion 36 and / or the frame-shaped portion 35 is not reinforced by other means, the extending portion 36 including the first extending portion 36A is thermally expanded. And it is particularly easy to deform due to heat shrinkage. In the present embodiment, the first extending portion 36A and the connecting portion 35 ′ connected to the first extending portion 36A of the frame-like portion 35 are included in the foamed resin included in the non-connecting portion 35 ″ of the frame-like portion 35. By deforming so as to include a foamed resin having a larger bending maximum point stress than that, deformation of the extending portion 36 including the first extending portion 36A can be more effectively suppressed.

  Further, as in the present embodiment, when the portion including the first frame portion 21 and the second frame portion 22 of the frame material 20 continuously circulates along the contour S of the vehicle seat member 10, Deformation due to thermal stress is suppressed over the entire circumference of the frame-shaped portion 35. For this reason, it is a case where the extending portion 36 is formed of a foamed resin having the same bending maximum point stress as that of the non-connecting portion 35 '' of the frame-shaped portion 35, and the extending portion 36 and / or the frame-shaped portion When the part 35 is not reinforced by other means, the extending part 36 formed inside the frame-like part 35 is more easily deformed. Even in such a case, in this embodiment, as described above, the expanded portion 36 is a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35. By deforming so as to include, the deformation of the extending portion 36 can be more effectively suppressed.

4). About the manufacturing method of the vehicle seat member 10 The manufacturing method of the vehicle seat member 10 is demonstrated below, referring FIG. In FIG. 5, each step of the manufacturing method will be described with reference to a schematic cross-sectional view at a position corresponding to the cross-sectional view taken along the line II of FIG. 4. In FIG. 6, each process of a manufacturing method is demonstrated with the typical sectional drawing in the position corresponding to the II-II arrow sectional drawing shown in FIG.

  In the embodiment described below, the first extending portion 36A of the extending portion 36 of the foamed resin molded body 30 and the portion connected to the first extending portion 36A of the connecting portion 35 ′ of the frame-like portion 35 are provided. This is an example in which the bending maximum point stress is increased by making the expansion ratio of the foamed resin constituting the foamed resin smaller than that of the foamed resin constituting the non-connecting portion 35 ″ of the frame-like portion 35.

  The outline of the manufacturing method of the vehicle seat member 10 of this embodiment is as follows. As shown in FIGS. 5 (A) and 6 (A), the frame material 20 is disposed so as to be positioned in the cavity 73 of the mold 7, and then expandable resin particles containing a resin and a foaming agent are preliminarily prepared. The pre-foamed resin particles 30A and 30B that have been foamed are filled. Next, as shown in FIGS. 5B and 6B, the pre-foamed resin particles 30 </ b> A are foamed by supplying steam into the mold 7, and the foamed resin molded body 30 is molded. Thereafter, as shown in FIGS. 5C and 6C, the foamed resin molded body 30 is removed from the mold 7 together with the frame material 20, and is cooled by cooling or the like.

  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 molding. 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, the extending portion 36 is formed of a foamed resin having the same bending maximum point stress as the non-connecting portion 35 '' of the frame-shaped portion 35, and the extending portion 36 and / or the frame-shaped portion 35 is When not reinforced by other means, as shown in FIG. 7A, the foamed resin molded body 30 is molded with the molding die 7 including the first mold 71 and the second mold 72, and the structure shown in FIG. As shown in FIG. 3, the foamed resin molded body 30 is thermally contracted immediately after molding until the foamed resin molded body 30 is released from the mold 7 and the foamed resin molded body 30 dissipates heat. At this time, since both sides of the extended portion 36 where the frame material 20 does not exist are restrained by the frame-like portion 35 where the second frame portion 22 of the frame material 20 exists, the extended portion 36 is compressed as thermal stress. Stress and tensile stress act unevenly, and the extended portion 36 is easily deformed so as to bend upward from the center.

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, in the plan view of the vehicle seat member 10, the frame material 20 is arranged such that the first frame portion 21 and the second frame portion 22 of the frame material 20 are arranged along the contour S of the vehicle seat member 10. It arrange | positions in the shaping | molding die 7 (arrangement | positioning process).
As the mold 7, a closed mold having a large number of small holes can be used.

  As shown in FIGS. 5 (A) and 6 (A), 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, the molding die 7 is molded. A cavity 73 corresponding to the foamed resin molded body 30 is formed in the mold 7.

  Next, as shown in FIG. 5 (A) and FIG. 6 (A), after the first mold 71 and the second mold 72 in which the frame material 20 is disposed are temporarily clamped, the pre-foamed resin The particles 30A and 30B are filled and clamped.

  At this time, in the foamed resin molded body 30 to be manufactured, the position in the cavity 73 corresponding to the portion where the foamed resin having a large bending maximum point stress is required is filled with the pre-foamed resin particles 30A having a small bulk ratio. The position within the cavity 73 corresponding to a portion other than the portion where the foamed resin having a large bending maximum point stress is required in the foamed resin molded body 30 to be manufactured is filled with the pre-foamed resin particles 30B having a large bulk ratio. To do. Specifically, in this embodiment, the cavity corresponding to the first extending portion 36A of the extending portion 36 and the portion connected to the first extending portion 36A of the connecting portion 35 ′ of the frame-like portion 35. 73 is filled with the pre-expanded resin particles 30A, and the first extending portion 36A of the extending portion 36 and the connecting portion 35 ′ of the frame-like portion 35 other than the portion connected to the first extending portion 36A. The pre-expanded resin particles 30B whose bulk multiple is larger than that of the pre-expanded resin particles 30A are filled in the positions in the cavity 73 corresponding to the extending portions 36 and the frame-shaped portions 35.

Next, as shown in FIG. 5B, the inside of the cavity 73 of the mold 7 is heated with water vapor or the like to secondary-foam the pre-foamed resin particles 30A and 30B, and the gap between the pre-foamed resin particles 30A and 30B. And pre-foamed resin particles 30A, 30B are fused together to form a foamed resin molded body 30 (molding step).
The fusion rate between the expanded particles derived from the pre-expanded resin particles in the expanded resin molded body 30 is not particularly limited, but is 50 to 100%, more preferably 70 to 100%, and more preferably 90 to 100%.

Here, the fusion rate is the foamed particle that breaks inside the particle out of the total number of foamed particles derived from the pre-foamed resin particles that appears on the cross section when the foamed resin molded body 30 is bent and broken. The percentage of the number is expressed as a percentage. Specifically, the fusion rate can be measured by the following procedure. A cutting line having a depth of about 5 mm is made with a cutter knife along the center of the foamed resin molding. Thereafter, the foamed resin molded body is manually divided into two along the cut line. Regarding the foamed particles in the fracture surface, the number (a) of particles broken in the particles and the number (b) of particles broken at the interface between the particles in an arbitrary range of 100 to 150 are counted. A value obtained by substituting the result into the formula [(a) / ((a) + (b))] × 100 is defined as a fusion rate (%).
The fusion rate can be controlled, for example, by controlling the amount of heat at the time of heating and foaming.

  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 formed extending portion 36 includes a foamed resin having a smaller expansion ratio and a larger bending maximum point stress than the foamed resin included in the non-connecting portion 35 ″ of the frame-shaped portion 35 in the first extending portion 36 </ b> A. In the present embodiment, the portion of the connection portion 35 ′ of the frame-shaped portion 35 that is connected to the first extending portion 36 </ b> A also has a foaming multiple than the foamed resin included in the non-connection portion 35 ″ of the frame-shaped portion 35. Includes foamed resin with a small bending maximum point stress. The molded frame-like portion 35 embeds the first frame portion 21 and the second frame portion 22 in the frame material 20 and forms the contour S of the vehicle seat member 10. The formed extending portion 36 extends such that the first extending portion 36A extends between the pair of side portions 35c, 35c of the frame-shaped portion 35, and the second extending portions 36B, 36B are The frame portion 35 extends so as to pass between the front portion 35a and the rear portion 35b.

  Next, the foamed resin molded body 30 is 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 molding die 7, the foamed resin molded body 30 contracts by releasing the residual heat at the time of molding.

  In the embodiment, the first extending portion 36 </ b> A is configured to include a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion 35 ″ of the frame-like portion 35. The rigidity of the extending portion 36A is increased. As a result, it is possible to suppress deformation due to thermal stress in the extending portion 36 including the first extending portion 36A. As a result, the vehicle seat member 10 with high dimensional accuracy can be manufactured. According to the present embodiment, the non-connecting portion 35 '' of the frame-shaped portion 35 can be made of a foamed resin having a large expansion ratio. Therefore, the overall weight increase and cost increase of the foamed resin molded body 10 are as follows. small. Moreover, according to this embodiment, since reinforcement, such as forming the 1st extension part 36A of the extension part 36 thickly, is unnecessary, possibility that a design and a use will be restrict | limited is low.

  In the present embodiment, the frame material 20 has a second frame portion 22, and the opposing portions 22 a and 22 a facing each other across the space inside the frame-shaped portion 35 are continuous in the second frame portion 22. It has a continuous part. When the foamed resin molded body 30 is molded, the extending portion 36 is formed so as to have a first extending portion 36A extending between the facing portions 22a and 22a. Therefore, both sides of the first extending portion 36A of the extending portion 36 are restrained by the side portions 35c and 35c of the frame-like portion 35 in which the opposing portions 22a and 22a of the second frame portion 22 of the frame material 20 are embedded. Therefore, as shown in FIG. 7, the first extending portion 36 </ b> A is formed of a foamed resin having the same bending maximum point stress as that of the non-connecting portion 35 ″ of the frame-like portion 35. When the part 36 and / or the frame-like part 35 are not reinforced by other means, the extending part 36 including the first extending part 36A is easily deformed by thermal contraction. In particular, since the portion including the first frame portion 21 and the second frame portion 21 of the frame material 20 is continuously circulated along the contour S of the vehicle seat member 10, such deformation is likely to occur. In the present embodiment, the first extending portion 36A, which is one of the extending portions of the extending portion 36, has a bending maximum point more than the foamed resin included in the non-connecting portion 35 '' of the frame-like portion 35 during the molding process. By molding the foamed resin molded body 30 so as to include a foamed resin having a large stress, the first extending portion 36A and the extending portion 36 including the first extending portion 36 can be reinforced and the above deformation can be suppressed.

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 vehicle seat member 10 according to the first embodiment in the longitudinal direction of the contour S of the vehicle seat member 10 in the extending portion 36. In addition to the extending first extending portion 36A, the second extending portions 36B and 36B extending in the short direction are the bending maximum points than the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35. It is a point including a foamed resin having a large stress. The same configurations as those of the first embodiment are denoted by the same reference numerals and detailed description thereof is omitted.

  In the present embodiment, out of the extending portion 36, the first extending portion 36A and the second extending portions 36B and 36B are more than the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35, respectively. The extending portion 36 is reinforced by forming the foamed resin molded body 30 so as to include a foamed resin having a large bending maximum point stress. Thereby, even if the extending part 36 is thermally expanded or contracted, deformation of the extending part 36 due to thermal stress can be suppressed, and the dimensional accuracy of the vehicle seat member 10 can be ensured.

  In the present embodiment, the portion connected to the first extending portion 36A of the connecting portion 35 ′ of the frame-shaped portion 35 is also bent more than the foamed resin included in the non-connected portion 35 ″ of the frame-shaped portion 35. By forming the foamed resin molded body 30 so as to include the foamed resin having a large point stress, it is possible to more efficiently suppress the extension portion 36 from being deformed.

  In the present embodiment, the frame member 20 has a structure in which a first frame portion 21 and a portion 22b along the rear edge portion sB of the second frame portion 22 facing the first frame portion 21 are continuous. The first frame portion 21 and the portion 22b of the second frame portion 22 along the rear edge sB are embedded in the frame-shaped portion 35, and the second extended portion 36B of the extended portion 36, 36B is formed so that it may extend over between the 1st frame part 21 and the part 22b along the back edge part sB among the 2nd frame parts 22, respectively. In this configuration, since both sides of the second extending portions 36B and 36B of the extending portion 36 are restrained, the second extending portions 36B and 36B of the extending portion 36 are temporarily disconnected from the frame-shaped portion 35. In the case where it is formed of a foamed resin having the same bending maximum point stress as that of the portion 35 ″ and the extending portion 36 and / or the frame-like portion 35 is not reinforced by other means, the second extending portion The extending part 36 including 36B and 36B is particularly easily deformed by thermal expansion and thermal contraction. In the present embodiment, the second extending portions 36B and 36B are molded so as to include a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35. 2 Deformation of the extending portion 36 including the extending portions 36B and 36B can be more effectively suppressed.

Manufacture of the vehicle seat member 10 according to the second embodiment can be performed in the same procedure as in the first embodiment. Also in the second embodiment, the foamed resin constituting the portion connected to the first extending portion 36A of the extending portion 36 of the foamed resin molded body 30 and the connecting portion 35 ′ of the frame-like portion 35 is formed into a frame shape. This is an example in which the bending maximum point stress is increased by making the expansion ratio smaller than that of the foamed resin constituting the non-connected portion 35 ″ of the portion 35.
First, the frame material 20 is formed so that the first frame portion 21 and the second frame portion 22 of the frame material 20 are arranged along the contour S of the vehicle seat member 10 in a plan view of the vehicle seat member 10. Place in the mold (placement process). Here, the mold is composed of a first mold and a second mold, and when the first mold and the second mold are clamped, a cavity corresponding to the foamed resin molded body 30 is formed in the mold. It is configured.

  Next, pre-expanded resin particles obtained by pre-expanding expandable resin particles containing a resin and a foaming agent after temporarily clamping (cracking) the first mold and the second mold in which the frame material 20 is disposed are used. Fill and clamp. At this time, the cavity corresponding to the first extension part 36A and the second extension part 36B in the extension part 36 and the part connected to the first extension part 36A in the connection part 35 'of the frame-like part 35. 73 is filled with pre-expanded resin particles having a relatively small bulk multiple, and a spare having a relatively large bulk multiple is placed at a position in the cavity 73 corresponding to the other part of the extending portion 36 and the frame-shaped portion 35. Fill with foamed resin particles.

  Next, the inside of the mold cavity is heated with steam or the like to secondary-foam the pre-foamed resin particles, filling the gaps between the pre-foamed resin particles and fusing the pre-foamed resin particles together Then, the foamed resin molded body 30 is molded (molding process).

  Thereby, the foamed resin molded body 30 including the frame-shaped portion 35 and the extending portion 36 can be molded in the mold. The molded extension part 36 includes a foamed resin having a maximum point stress larger than that of the foamed resin included in the non-connecting part 35 '' of the frame-like part 35 in the first extension part 36A and the second extension part 36B. . In the present embodiment, the portion connected to the first extending portion 36A in the connecting portion 35 ′ of the frame-shaped portion 35 is also the maximum bending point than the foamed resin included in the non-connected portion 35 ″ of the frame-shaped portion 35. Includes foamed resin with high stress. The molded frame-like portion 35 embeds the first frame portion 21 and the second frame portion 22 in the frame material 20 and forms the contour S of the vehicle seat member 10. The formed extending portion 36 extends such that the first extending portion 36A extends between the pair of side portions 35c, 35c of the frame-shaped portion 35, and the second extending portions 36B, 36B are The frame portion 35 extends so as to pass between the front portion 35a and the rear portion 35b.

  Next, the foamed resin molded body 30 is removed from the mold, and the vehicle seat member 10 of the present embodiment in which the foamed resin molded body 30 and the frame material 20 are integrated can be obtained. Here, after removing the foamed resin molded body 30 from the middle of the mold, the residual heat at the time of molding dissipates, and the foamed resin molded body 30 contracts.

  In the present embodiment, even if the extending portion 36 is thermally contracted, the first extending portion 36A and the second extending portions 36B and 36B are more than the foamed resin included in the non-connecting portion 35 '' of the frame-like portion 35. Since it is configured to include a foamed resin having a large bending maximum point stress, it is possible to suppress deformation due to thermal stress of the first extending portion 36A, the second extending portions 36B and 36B, and the extending portion 36 including these. it can. As a result, the vehicle seat member 10 with high dimensional accuracy can be manufactured.

  In the present embodiment, one end of the second extending portions 36B and 36B of the extending portion 36 is restrained by the front portion 35a of the frame-shaped portion 35 in which the first framework portion 21 of the frame material 20 is embedded, The other end of the second extending portions 36B and 36B of the extending portion 36 is located behind the frame-shaped portion 35 in which the portion 22b along the rear edge sB of the second framework portion 22 of the frame material 20 is embedded. Restrained by the portion 35b. Similarly, as described with respect to the first embodiment, both sides of the first extending portion 36A of the extending portion 36 are also frame-like portions in which the opposing portions 22a and 22a of the second frame portion 22 of the frame material 20 are embedded. 35 is restrained by the side portions 35c and 35c. For this reason, it is assumed that the first extending portion 36A and the second extending portions 36B, 36B are formed of a foamed resin having the same bending maximum point stress as the non-connecting portion 35 '' of the frame-like portion 35. Thus, when the extending portion 36 and / or the frame-like portion 35 is not reinforced by other means, the extending portion 36 is easily deformed by heat shrinkage. Moreover, in the present embodiment, since the portion including the first frame portion 21 and the second frame portion 21 of the frame material 20 is continuously circulated along the contour S of the vehicle seat member 10, such a deformation is performed. Is particularly likely to occur. In the present embodiment, the first extending portion 36A and the second extending portions 36B and 36B of the extending portion 36 are bent more than the foamed resin included in the non-connecting portion 35 '' of the frame-shaped portion 35 during the molding process. By molding the foamed resin molded body 30 so as to include a foamed resin having a large point stress, the first extending portion 36A and the extending portion 36 including the same are reinforced, and the above deformation is suppressed.

  As mentioned above, although several 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 range of this invention described in the claim, it is various. The design can be changed.

[Example 1]
The vehicle seat member 10 of the first embodiment shown in FIGS. 1 to 6 was manufactured by in-mold foam molding.
The used mold 7 is such that the dimension of the foamed resin molded body 30 of the manufactured vehicle seat member 10 is 1260 mm in the longitudinal direction, 550 mm in the lateral direction, and 160 mm in thickness. Is formed.
An iron wire (SWM-B) having a diameter of 4.5 mm was used for the first frame portion 21 and the second frame portion 22 of the frame material 20.
The foamed resin molded body 30 was molded from a composite resin containing a polystyrene resin and a polyolefin resin.
In the foamed resin molded body 30, the first extending portion 36A of the extending portion 36 and the connecting portion 35 'connected to the first extending portion 36A of the frame-like portion 35 have a foaming ratio of 20 times. The resin was molded from a foamed resin having a bending maximum point stress of 592 kPa measured under the above conditions.
On the other hand, in the foamed resin molded body 30, portions other than the first extending portion 36 </ b> A of the extending portion 36 and the connecting portion 35 ′ connected to the first extending portion 36 </ b> A in the frame-like portion 35 (frame-like portion). 35 unconnected portions 36 '') were molded from a foamed resin having an expansion ratio of 30 times and a bending maximum point stress measured under the above conditions of 354 kPa.
The vehicle seat member 10 was manufactured according to the procedure described in this specification with respect to the first embodiment.
After the molding process, the mold 7 was removed and allowed to cool to room temperature.
After being allowed to cool, the first extending portion 36A of the extending portion 36 of the foamed resin molded body 30 protrudes with its center portion curved upward and protruding (the case of Comparative Example 1 described later is shown in FIG. 7B). ). When the amount of protrusion (maximum deformation amount) was measured from the position of the central portion of the first extension portion 36A when it was assumed that the first extension portion 36A was not curved at all, the maximum deformation amount was 6.0 mm. Met.
The maximum allowable deformation amount of the vehicle seat member 10 is 6 mm. The maximum deformation (6.0 mm) of the vehicle seat member 10 of Example 1 was within an allowable range.

[Example 2]
The vehicle seat member 1 of the first embodiment shown in FIGS. 1 to 6 was manufactured by in-mold foam molding.
Of the foamed resin molded body 30, the first extending portion 36 </ b> A of the extending portion 36 and the connecting portion 35 ′ connected to the first extending portion 36 </ b> A of the frame-like portion 35 have an expansion ratio of 15 times. The vehicle seat member 1 of Example 2 was manufactured under the same conditions as in Example 1 except that it was molded from a foamed resin having a bending maximum point stress measured under the above conditions of 774 kPa.
The maximum amount of deformation of the vehicle seat member 1 of Example 2 was 5.1 mm, which was within an allowable range.

[Example 3]
The vehicle seat member 1 of the first embodiment shown in FIGS. 1 to 6 was manufactured by in-mold foam molding.
In the foamed resin molded body 30, the first extending portion 36 </ b> A of the extending portion 36 and the connecting portion 35 ′ connected to the first extending portion 36 </ b> A in the frame-like portion 35 have a foaming ratio of 10 times. The vehicle seat member 1 of Example 3 was manufactured under the same conditions as in Example 1 except that it was molded from a foamed resin having a bending maximum point stress measured under the above conditions of 873 kPa.
The maximum deformation amount of the vehicle seat member 1 of Example 3 was 3.9 mm, which was within an allowable range.

[Example 4]
The vehicle seat member 1 of the first embodiment shown in FIGS. 1 to 6 was manufactured by in-mold foam molding.
In the foamed resin molded body 30, the first extending portion 36 </ b> A of the extending portion 36 and the connecting portion 35 ′ connected to the first extending portion 36 </ b> A in the frame-like portion 35 have a foaming ratio of 5 times. The vehicle seat member 1 of Example 4 was manufactured under the same conditions as in Example 1 except that it was molded from a foamed resin having a bending maximum point stress measured under the above conditions of 1008 kPa.
The maximum deformation amount of the vehicle seat member 1 of Example 4 was 2.8 mm, which was within an allowable range.

[Comparative Example 1]
Comparative Example 1 under the same conditions as in Example 1 except that the entire foamed resin molded body 30 was molded from a foamed resin having a foaming ratio of 30 times and a bending maximum point stress measured under the above conditions of 354 kPa. The vehicle seat member was manufactured.
The maximum deformation amount of the vehicle seat member of Comparative Example 1 was 8.5 mm, which greatly exceeded the allowable maximum deformation amount of 6 mm.

1: vehicle seat, 7: molding die, 10: vehicle seat member, 20: frame material, 21: first frame portion, 22: second frame portion, 30: foamed resin molded body, 35: frame-shaped portion, 36: Extension part, 36A: 1st extension part, 36B: 2nd extension part

Claims (8)

A method of manufacturing a vehicle seat member comprising a frame material and a foamed resin molded body in which at least a part of 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;
A frame-shaped portion that embeds at least a part of the frame material and forms an outline of the vehicle seat member in the mold, and the frame-shaped portion so as to pass the frame-shaped portion inside the frame-shaped portion A molding step of molding a foamed resin molded body including an extending portion extending inward from
Including
In the molding step, the extending part includes a foamed resin having a larger bending maximum point stress than a foamed resin included in a non-connecting part other than a connecting part connected to the extending part in the frame-shaped part. A method for manufacturing a vehicle seat member, comprising molding the foamed resin molded body. 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 foamed resin molded body is molded such that the extending portion extends 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 molding step, the extending portion includes a first extending portion extending along at least the longitudinal direction over the opposing portion of the frame-shaped portion, and the first extending portion is The foamed resin molded body is molded so as to include a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connected portion of the frame-shaped part.
The manufacturing method of the vehicle seat member of Claim 1 or 2.   The method for manufacturing a vehicle seat member according to any one of claims 1 to 3, wherein in the arranging step, at least a part of the frame material 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 at least a part of 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-like portion that embeds at least a part of the frame material and forms an outline of the vehicle seat member, and the frame-like portion that extends over the frame-like portion inside the frame-like portion. An extending portion extending inward from the shape portion,
In the foamed resin molded body, the extending portion includes a foamed resin having a bending maximum point stress larger than a foamed resin included in a non-connecting portion other than a connecting portion connected to the extending portion in the frame-shaped portion. 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 5. 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 5 or 6, wherein the first extending portion includes a foamed resin having a bending maximum point stress larger than that of the foamed resin included in the non-connecting portion of the frame-shaped portion.   The said frame material is a vehicle seat member of any one of Claims 5-7 currently circling along the outline of the vehicle seat member.

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