JP2019014217A - Manufacturing method of seat cushion material, and foaming mold for manufacturing the same - Google Patents

Abstract

To provide a manufacturing method capable of manufacturing a seat pad provided with a latching member for a seat cover on the bottom surface of a suspending groove while suppressing the occurrence of a defect including a void, and a foaming mold for the manufacturing the same.SOLUTION: Provided is a manufacturing method of a cushion pad having a suspending groove provided with a clip 30 on the bottom. An urethane foaming mold 50 is provided with a lower mold 51 having a lower cavity surface 51a in accordance with a seating surface side shape of the cushion pad, and an upper mold 52. The lower cavity surface 51a is formed with the suspending groove and formed with a front protrusion 51b capable of temporarily fixing the clip 30, a first surface 51a1 inclining upwards from the front protrusion 51b, and a second surface 51a2 inclining downwards from the front protrusion 51b. A portion corresponding to a temporary fixing part of the clip 30 of the second surface 51a2 is provided with an approximately U-shaped standing wall 51d in a top view. A foam urethane resin material M is injected on the first surface 51a1 and on the second surface 51a2 including the front protrusion 51b side of the standing wall 51d.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a method for manufacturing a seat cushion material constituting a vehicle seat and a foaming mold for manufacturing the seat cushion material.

  In a vehicle seat, when fixing a seat cover, which is a skin material, to a seat pad surface, which is a cushion material, a cloth or resin suspension member attached to the back surface of the seat cover in a hanging groove portion recessed in the seat pad surface There is something that is pulled in and fixed. In the invention disclosed in Patent Document 1, a hanging groove portion that extends in the seat front-rear direction is provided on the seating surface of the foamed resin seat pad, and a locking member that locks the suspension member on the bottom surface portion of the hanging groove portion Is provided. The locking member is attached to the seat pad by being integrally foam-molded in a state of being disposed at a predetermined position in the cavity of the molding die at the time of foam-molding the seat pad.

Japanese Patent Laid-Open No. 2006-88365

  In the manufacturing method of the seat pad described in the above-mentioned Patent Document 1, a method is used in which a ridge that forms a hanging groove portion of the seat pad is provided on the cavity surface of the lower mold in the upper and lower molds having the cavity for molding the seat pad. Is done. Then, foaming of the seat pad is performed in a state where the locking member is temporarily fixed to a predetermined position of the top of the ridge, and the seat pad is integrated with a part of the locking member embedded in the bottom surface portion of the hanging groove portion. I got a seatpad. Here, if there is a difference in height between the cavity surfaces on both sides in the longitudinal direction of the ridges, the resin material that rises while foam-curing from both sides of the ridges does not meet at the top of the ridges, and the top of the ridges on either side It tended to flow over. In such a case, if the locking member is temporarily fixed to the top of the ridge, a turbulent flow of the resin raw material that rises while foaming and hardening around the locking member is likely to cause defects such as voids around the locking member. There was a problem.

  The present invention has been devised in view of these points. It is an object of the present invention to provide a manufacturing method capable of manufacturing a seat pad provided with a locking member for a seat cover on a bottom surface portion of a hanging groove portion while suppressing generation of defects such as voids, and a foaming mold for manufacturing the manufacturing method. .

  1st invention of this invention is a manufacturing method of the seat cushion material made from a foaming resin which has the suspension groove by which the latching member which draws and latches a part of seat cover was arrange | positioned in the bottom part, Comprising: This seat cushion The material molding die includes a lower mold having a lower cavity surface corresponding to the shape on the seating surface side of the seat cushion material, and an upper mold having an upper cavity surface corresponding to the shape opposite to the seating surface of the seat cushion material And a convex strip provided with a temporary fixing portion that can form the suspension groove on the lower cavity surface of the lower mold and can temporarily fix the locking member at a predetermined position on the top. A first surface portion is formed on one side of the lower cavity surface in the longitudinal direction of the ridge to extend horizontally or upward as it is separated from the ridge. A second surface portion is formed on the other side in the longitudinal direction of the protrusion on the cavity surface so as to extend downward as it is separated from the protrusion, and a portion corresponding to the temporary fixing portion of the second surface portion is formed. Is provided with a standing wall formed in a substantially U shape with the opening side facing the ridge in a top view and extending upward, and on the first surface portion of the lower mold and on the ridge side of the standing wall A foamed resin raw material is injected into the second surface portion including the upper mold and the upper mold is closed to perform foam molding.

  If the standing wall is not provided, the foamed resin material injected into the first surface portion approaches the direction of the ridge while foaming and solidifying. On the other hand, after the foamed resin raw material injected into the second surface portion flows downward, it approaches while projecting to solidify in the direction of the ridges. Due to the difference in the arrival time of the foamed resin material to the ridge, turbulent flow is generated around the temporarily fixed locking member, and defects such as voids are likely to occur. However, according to the first aspect of the invention, since the foamed resin raw material is injected onto the second surface portion including the standing wall provided on the portion corresponding to the temporary fixing portion and including the protruding strip side of the standing wall, some of the raw material is protruded from the raised wall. It is possible to reduce the deviation of the arrival time of the foamed resin raw material injected into the first surface portion to the ridges and held on the strip side. As a result, it is possible to suppress the occurrence of defects such as voids due to turbulent flow around the temporarily fixed locking member.

  According to a second aspect of the present invention, in the first aspect, the vertical height of the upright wall from the lower cavity surface is about 2/5 of the vertical height of the ridge from the lower cavity surface. It is characterized by being set to.

  According to the second invention, the height in the vertical direction from the lower cavity surface of the standing wall is smaller than that of the ridge, so that the depth of the groove-like portion formed on the seating surface side of the seat cushion material becomes shallow and opens. It becomes difficult to make it difficult to feel the presence of the groove-like portion through the seat cover.

  According to a third aspect of the present invention, in the first aspect or the second aspect of the invention, the ridge is formed in a substantially inverted U shape with a transverse section opening downward, and the locking member is the temporary fixing A plate-like substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge when temporarily fixed to the portion, and extends downward from the substrate portion with a predetermined distance from the ridge. And a pair of engaging protrusions that engage with the temporary fixing portion.

  According to the third invention, the locking member can be simply temporarily fixed by engaging the pair of engaging protrusions with the temporarily fixed portion. In addition, since the base plate portion is disposed over the width in the direction perpendicular to the longitudinal direction of the suspension groove in the seat cushion material on the side opposite to the seating surface from the bottom of the suspension groove, the locking member is seat cushion The material can be held strongly.

  A fourth invention of the present invention is a foaming mold for manufacturing a seat cushion material made of foamed resin having a hanging groove in which a locking member that pulls and locks a part of the seat cover is disposed at the bottom, A lower mold having a lower cavity surface corresponding to the shape on the seating surface side of the seat cushion material, and an upper mold having an upper cavity surface corresponding to a shape opposite to the seating surface of the seat cushion material. The lower cavity surface of the mold is formed with a ridge that extends upward and is provided with a temporary fixing portion that can form the suspension groove and temporarily fix the locking member at a predetermined position on the top. A first surface portion extending in the horizontal direction or upward as the distance from the protrusion is increased is formed on one side in the longitudinal direction of the protrusion on the lower cavity surface, and the protrusion on the lower cavity surface is formed. A second surface portion is formed on the other side in the longitudinal direction so as to extend downward as it is separated from the protrusion, and a portion corresponding to the temporary fixing portion of the second surface portion is formed with the protrusion in a top view. A standing wall formed in a substantially U shape with the opening side facing the strip and extending upward is provided on the first surface portion of the lower mold and the second surface portion including the convex strip side of the standing wall The upper portion is a portion into which the foamed resin raw material is injected.

  If the standing wall is not provided, the foamed resin material injected into the first surface portion approaches the direction of the ridge while foaming and solidifying. On the other hand, after the foamed resin raw material injected into the second surface portion flows downward, it approaches while projecting to solidify in the direction of the ridges. Due to the difference in the arrival time of the foamed resin material to the ridge, turbulent flow is generated around the temporarily fixed locking member, and defects such as voids are likely to occur. However, according to the fourth aspect of the invention, the standing resin is provided on the portion corresponding to the temporary fixing portion, and the foamed resin raw material is injected onto the second surface portion including the protruding stripe side of the standing wall. It is possible to reduce the deviation of the arrival time of the foamed resin raw material injected into the first surface portion to the ridges and held on the strip side. As a result, it is possible to suppress the occurrence of defects such as voids due to turbulent flow around the temporarily fixed locking member.

  According to a fifth aspect of the present invention, in the fourth aspect, the vertical height of the standing wall from the lower cavity surface is about 2/5 of the vertical height of the ridge from the lower cavity surface. It is characterized by being set to.

  According to the fifth aspect of the present invention, since the vertical height from the lower cavity surface of the standing wall is smaller than that of the ridge, the depth of the groove-like portion formed on the seat cushion surface side of the seat cushion material becomes shallow and opens. It becomes difficult to make it difficult to feel the presence of the groove-like portion through the seat cover.

  According to a sixth aspect of the present invention, in the fourth or fifth aspect of the present invention, the ridge is formed in a substantially inverted U shape with a transverse section opening downward, and the locking member is the temporary fixing A plate-like substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge when temporarily fixed to the portion, and the temporary fixing of the ridge extending downward from the substrate portion at a predetermined interval And a pair of engaging protrusions engaged with the portion.

  According to the sixth invention, the locking member can be simply temporarily fixed by engaging the pair of engaging protrusions with the temporary fixing portion. In addition, since the base plate portion is disposed over the width in the direction perpendicular to the longitudinal direction of the suspension groove in the seat cushion material on the side opposite to the seating surface from the bottom of the suspension groove, the locking member is seat cushion The material can be held strongly.

It is a perspective view of the seat cushion using the cushion pad manufactured by one Embodiment of this invention. It is a top view of the cushion pad manufactured by the said embodiment. It is sectional drawing cut | disconnected and shown by the III-III line of FIG. It is a perspective view which shows the state by which the suspender was latched by the clip. It is sectional drawing which shows the type | mold which shape | molds the cushion pad which concerns on the said embodiment. FIG. 4 shows a cross section corresponding to FIG. 3. The cavity is in a hollow state. It is sectional drawing which shows the type | mold which shape | molds the cushion pad which concerns on the said embodiment. FIG. 4 shows a cross section corresponding to FIG. 3. The clip is attached to the lower mold. It is a figure which expands and shows the VII part of FIG. It is sectional drawing which shows the type | mold which shape | molds the cushion pad which concerns on the said embodiment. FIG. 4 shows a cross section corresponding to FIG. 3. The state which injected the foaming resin raw material in the cavity is shown. It is sectional drawing which shows the type | mold which shape | molds the cushion pad which concerns on the said embodiment. FIG. 4 shows a cross section corresponding to FIG. 3. The state in which the foamed resin material is cured while foaming is shown. It is sectional drawing which shows the type | mold which shape | molds the cushion pad which concerns on the said embodiment. FIG. 4 shows a cross section corresponding to FIG. 3. The cushion pad is in a molded state.

  The cushion pad 1 which is a seat cushion material manufactured by one Embodiment which concerns on the manufacturing method of this invention is demonstrated according to FIGS. In each figure, each direction of the automobile and the cushion pad 1 when the cushion pad 1 is attached to the floor of the automobile is shown by arrows. In the following description, the description regarding the direction is made based on this direction.

  FIG. 1 shows a seat cushion SC using a cushion pad 1 produced by the production method and the production foaming mold according to the present invention. The seat cushion SC is for a three-seat bench seat, and has a length in the left-right direction that is substantially the same as the width of the passenger compartment. The cushion pad 1 is covered with a cushion cover 2 that covers the surface thereof to form a seat cushion SC. Then, a seat back (not shown) having the same configuration is combined in a state of being erected at the rear end portion of the seat cushion SC and attached to the floor to constitute a rear seat. Here, the cushion pad 1 and the cushion cover 2 correspond to a “seat cushion material” and a “seat cover” in the claims, respectively.

As shown in FIGS. 1 to 4, the cushion pad 1 has a pair of left and right seat portions 1 </ b> A and a central seat portion 1 </ b> B disposed between the left and right seat portions 1 </ b> A. Moreover, the cushion pad 1 is formed from urethane foam obtained by foaming polyurethane resin, and its density is set to about 0.045 ± 0.005 g / cm ^3, for example. The cushion pad 1 includes a surface portion 10 having a shape and an area that occupies the entire surface of the seating surface, and a back surface portion 20 that forms the opposite side of the seating surface. The cushion pad 1 includes a buttocks support portion 11 that is a portion that supports the buttocks of the seated occupant of the left and right seat portions 1A, and a thigh support portion 12 that is a portion that supports the thighs of the seated occupants of the left and right seat portions 1A. It is equipped with. Although not shown, the center seat portion 1B is formed thinner than the buttock support portion 11 and the thigh support portion 12 in both the buttock support portion and the thigh support portion. Although not shown, frame-shaped wire frames are inserted in front, rear, left and right peripheral portions of the back surface portion 20 of the cushion pad 1. The frame not only functions as a skeleton of the cushion pad 1 but also functions as an attachment member when the cushion pad 1 is attached to the floor. The front surface portion 10 includes a pair of vertical grooves 13 extending in the front-rear direction on the left and right sides of the left and right seat portions 1A, a front horizontal groove 14 connecting the pair of vertical grooves 13 at a substantially central portion in the front-rear direction, and a rear horizontal groove connecting the rear end portions. 15 is formed. The vertical groove 13, the front horizontal groove 14, and the rear horizontal groove 15 are formed in a substantially U shape whose cross section is open upward. The back surface portion 20 is provided with a meat stealing hole 21 for weight reduction at a predetermined location that does not affect the cushion performance. Here, the front lateral groove 14 corresponds to a “hanging groove” in the claims.

  As shown in FIG. 2, two clips 30 are arranged side by side in the front-rear direction at the bottom of the vertical groove 13 corresponding to the left and right sides of the heel support 11. Two clips 30 are also arranged in the left and right direction at the bottom of the front lateral groove 14 and the rear lateral groove 15. That is, 16 clips 30 are arranged in the cushion pad 1 as a whole. Since all 16 clips 30 have the same shape and the same material, as a representative, the clip 30 disposed inside the front lateral groove 14 in the sheet width direction is shown in FIG. As shown in FIG. 4, the clip 30 is an integrally molded product of resin, and includes a plate-like substrate portion 31 and two locking portions 32 that rise upward from the substrate portion 31. Here, the clip 30 corresponds to a “locking member” in the claims.

  The substrate portion 31 has a substantially rectangular shape with the left-right direction as the longitudinal direction when viewed from above, and is provided with a pair of cutouts 31a extending so as to be close to each other in the front-rear direction at the center portion in the left-right direction. The substrate portion 31 is provided with four through holes 31b arranged in the left-right direction symmetrically with respect to a center line extending in the longitudinal direction through the center of the substrate portion 31. The notch 31a serves to weaken the torsional resistance of the substrate portion 31, and the through-hole 31b increases the strength of attaching the substrate portion 31 to the cushion pad 1 by the intrusion and solidification of the foamed urethane resin material M forming the cushion pad 1. Work.

  Two locking portions 32 are provided at positions that are symmetrical with respect to a center line that extends in the short direction through the center of the substrate portion 31. Since the two locking portions 32 have the same shape, the right locking portion 32 in FIG. 4 will be described as a representative. The locking portion 32 includes a pair of standing wall portions 32a that rises facing from the upper surface of the substrate portion 31, and a pair of locking claw portions 32b that are formed on the distal ends of the pair of standing wall portions 32a. The pair of standing wall portions 32a and the pair of latching claw portions 32b have a shape that is symmetrical with respect to a center line that passes through the center of the substrate portion 31 and extends in the longitudinal direction. The pair of standing wall portions 32a are formed so as to be separated from each other toward the upper tip side from the substrate portion 31, and can be elastically deformed in a direction in which the tip side is separated. The pair of locking claws 32b are formed to extend so as to be close to each other from the distal ends of the pair of standing walls 32a. As shown in FIGS. 3 and 4, the clip 30 includes a base plate portion 31 embedded in the cushion pad 1 of the bottom portion 14 a of the front horizontal groove 14, and a locking portion 32 facing the pair of standing wall portions 32 a inside the front horizontal groove 14. It is installed with the side exposed. The same applies to the rear lateral groove 15 of the substrate portion 31. Further, on the substrate portion 31, front and rear portions 31 c extending upward are provided before and after the locking portion 32. The upright portion 31c functions to limit the distance between the pair of standing wall portions 32a to be not more than a predetermined value. Here, the pair of standing wall portions 32a and the pair of locking claw portions 32b correspond to “a pair of engaging protrusions” in the claims.

  As shown in FIG. 4, the suspender 40 is attached to a portion corresponding to the vertical groove 13, the front horizontal groove 14, and the rear horizontal groove 15 of the cushion pad 1 on the back surface (surface opposite to the seating surface) of the cushion cover 2. Yes. The suspender 40 has a non-woven belt-like fabric body 41 whose upper end side is attached to the cushion cover 2 and a resin columnar body 42 attached to the lower end side (cushion pad 1 side) of the belt-like fabric body 41. doing. The suspender 40 is a unit in which a strip-shaped fabric body 41 having a constant width is supplied and integrated in a direction in which the front end side of the ridge is directed outward while extruding the columnar resin body 42 having a ridge shape in cross section. Here, the suspender 40 corresponds to “a part of the seat cover” in the claims.

  As shown in FIG. 4, the resin-made columnar body 42 of the suspender 40 has a pair of locking claws in the two locking portions 32 in which the distal end side of the bowl-shaped cross section is exposed inside the front horizontal groove 14 of the cushion pad 1. It is pressed between the tips of the part 32b. Then, the pair of standing wall portions 32a in the two locking portions 32 are separated from each other in the front-rear direction, and the resin columnar body 42 is received below the pair of locking claw portions 32b and returns to the original state. Accordingly, the resin columnar body 42 is attached in a state where the belt-like fabric body 41 side is locked by the locking claw portion 32 b and the cushion cover 2 is in contact with the surface portion 10 of the cushion pad 1.

  As shown in FIGS. 1 to 3, the front portion of the portion of the thigh support portion 12 of the cushion pad 1 where the clip 30 is disposed has a substantially U-shaped shape that opens rearward in a top view. A curved groove 16 is formed. As will be described later, the curved groove 16 is formed by the presence of a standing wall 51d that suppresses the occurrence of defects such as voids around the clip 30 that is integrally formed when the cushion pad 1 is foam-molded. The length of the open end (rear end) of the curved groove 16 in the left-right direction is slightly longer than the length of the clip 30 in the longitudinal direction. Further, the length in the front-rear direction from the opening end (rear end portion) of the curved groove 16 to the front end portion opposite to the opening end is formed slightly shorter than the length in the short direction of the clip 30. The shape of the curved groove 16 can be adjusted by the shape of the front lateral groove 14, the set position of the clip 30, and the like. Further, the shape of the transverse cross section of the curved groove 16 is formed in a substantially inverted U shape opening downward, and the length (depth) of the curved groove 16 in the vertical direction is 2 times the depth of the front transverse groove 14. It is set to about / 5.

  A method for manufacturing the cushion pad 1 and a foaming mold for manufacturing will be described with reference to FIGS. In addition, the display of the direction in FIGS. 5-10 shall match the direction of the cushion pad 1. FIG. As shown in FIG. 5, the urethane foam mold 50 for molding the cushion pad 1 includes a lower mold 51 and an upper mold 52 that can be opened and closed with respect to the lower mold 51. The lower mold 51 and the upper mold 52 are each provided with a mold temperature control function for molding urethane foam resin and a lock mechanism (not shown) when the mold is closed. A lower cavity surface 51 a having a shape corresponding to the surface portion 10 of the cushion pad 1 is formed in the lower mold 51. An upper cavity surface 52 a having a shape corresponding to the back surface portion 20 of the cushion pad 1 is formed in the upper mold 52. In a state where the upper mold 52 is closed with respect to the lower mold 51, a cavity 53 surrounded by the lower cavity surface 51a and the upper cavity surface 52a is formed between the lower mold 51 and the upper mold 52. The lower cavity surface 51a includes a front convex strip 51b having a shape corresponding to the front lateral groove 14, a rear convex strip 51c having a shape corresponding to the rear lateral groove 15, and a standing wall 51d having a shape corresponding to the curved groove 16. It is formed to extend upward substantially perpendicular to the surface 51a. In the lower cavity surface 51a, a portion between the front ridge 51b and the rear ridge 51c is formed as a first surface portion 51a1 inclined forward and downward toward the front ridge 51b. Moreover, in the lower cavity surface 51a, the part from the front protruding item | line 51b to a front-end part is formed as the 2nd surface part 51a2 which inclines back upward toward the front protruding item | line 51b. Furthermore, in the 2nd surface part 51a2, the part between the front protruding item | line 51b and the standing wall 51d is formed as the standing wall upper surface part 51a21, and another part is formed as the standing wall lower surface part 51a22. Here, the urethane foam mold 50 and the front protrusion 51b correspond to the “mold” and “projection” in the claims, respectively.

  As shown in FIG. 6, the clip 30 is temporarily fixed at a position corresponding to the attachment portion of the clip 30 of the front lateral groove 14 at the upper end portion which is the top portion of the front protrusion 51 b of the lower mold 51. Similarly, the clip 30 is temporarily fixed at a position corresponding to the attachment portion of the clip 30 in the rear lateral groove 15 at the upper end portion which is the top portion of the rear convex strip 51c of the lower mold 51. Here, as shown in FIG. 7, the constricted portion 51 b 1 in which the distal end sides of the pair of locking claws 32 b of the clip 30 are temporarily locked to the portion where the clip 30 is temporarily fixed, as shown in FIG. 7. Is provided. The constricted portion 51 b 1 is provided at four positions on the front convex strip 51 b corresponding to the locking portion 32 of the clip 30. The clip 30 temporarily fixed to the constricted portion 51b1 is held so as not to be detached in the process of foam molding of the cushion pad 1. After the foam molding, the clip 30 is detached from the constricted portion 51b1 when the molded cushion pad 1 is removed. It is configured so as to be removed from the cushion pad 1 together. In addition, although description is abbreviate | omitted, it is the same also in the rear protruding item | line 51c, and also the protruding item | line provided corresponding to the vertical groove 13 is the same. Here, the upper end portion of the front protrusion 51b provided with the constricted portion 51b1 corresponds to a “temporary fixing portion” in the claims.

  Next, as shown in FIG. 8, the foamed urethane resin raw material M is injected onto the lower cavity surface 51 a of the lower mold 51 to close the upper mold 52. At this time, the urethane foam resin material M1 is injected into the first surface portion 51a1. Moreover, the urethane foam resin raw material M2 is injected into the standing wall upper surface portion 51a21 in the second surface portion 51a2. And the foaming urethane resin raw material M3 is inject | poured into the standing wall lower surface part 51a22 in the 2nd surface part 51a2. The foamed urethane resin raw material M3 may not be injected into the standing wall lower surface portion 51a22, and the foamed urethane resin raw material M2 may be injected only into the standing wall upper surface portion 51a21 so that part of the foamed urethane resin raw material M3 flows forward. Injection of the urethane foam raw material M2 into 51a21 is essential. Here, the standing wall upper surface portion 51a21 corresponds to the “projection side of the standing wall” in the claims. The foamed urethane resin material M corresponds to the “foamed resin material” in the claims.

  As shown in FIG. 9, the foamed urethane resin material M1 increases in volume while foaming and curing on the first surface portion 51a1. Similarly, the volume of urethane foam resin material M2 is increased on the standing wall upper surface portion 51a21 and the volume of urethane foam resin material M3 is increased on the standing wall lower surface portion 51a22 while being foam-cured. At this time, the urethane foam resin raw material M1 expands from the position close to the front convex stripe 51b before and after the front convex stripe 51b, and the foamed urethane resin raw material M2 expands rearward and upward. At the same time, the upper part of the clip 30 abuts. As a result, the foamed urethane resin material M1 does not flow over the upper portion of the clip 30 forward, and turbulent flow at the peripheral portion of the clip 30 is less likely to occur, so that occurrence of defects such as voids can be suppressed. If there is no standing wall 51d, the foamed urethane resin material M2 injected onto the standing wall upper surface portion 51a21 flows forward and downward to increase the volume while foaming and hardening together with the foamed urethane resin material M3. . Then, the clip 30 is delayed from reaching the temporarily fixed portion, and the foamed urethane resin raw material M1 flows over the upper portion of the clip 30 forward, so that defects such as voids are easily generated. The reason why the standing wall is not provided behind the rear ridge 51c is that the occurrence of a defect such as a void hardly affects the seating comfort and the like because it is a part away from the seating surface. If the occurrence of defects such as voids becomes a problem even in the portion where the clip 30 of the rear ridge 51c is temporarily fixed, take measures to provide a standing wall in the vicinity of the front ridge 51b. Is possible. Needless to say, this measure is also possible in the ridges provided corresponding to the longitudinal grooves 13.

  As shown in FIG. 10, the foamed urethane resin raw material M1, the foamed urethane resin raw material M2, and the foamed urethane resin raw material M3 each increase in volume while being foam-cured to fill the cavity 53. At this time, the foamed urethane resin raw material M1, the foamed urethane resin raw material M2, and the foamed urethane resin raw material M3 are united at their boundaries and integrally hardened to form the cushion pad 1 in the cavity 53. A clip 30 and a frame are integrally formed in the cushion pad 1. The cushion pad 1 having been cured is opened from the lower mold 51 by opening the upper mold 52 with respect to the lower mold 51. At this time, the clip 30 is disengaged from the constricted portion 51b1 of the front protrusion 51b in a state where the base plate portion 31 is embedded in the cushion pad 1 of the bottom portion 14a of the front lateral groove 14.

  In the manufacturing process and the foaming mold as described above, the following effects are exhibited. The foamed urethane resin raw material M1 injected into the first surface portion 51a1 of the lower mold 51 approaches the front front ridge 51b while foaming and solidifying from a position close to the front ridge 51b. Similarly, the foamed urethane resin raw material M2 injected into the standing wall upper surface portion 51a21 of the lower mold 51 also approaches the rear front convex stripe 51b while foaming and solidifying from a position close to the front convex stripe 51b. The foamed urethane resin material M1 and the foamed urethane resin material M2 abut on the upper portion of the clip 30 almost simultaneously. As a result, it is possible to suppress the occurrence of defects such as voids due to turbulent flow around the clip 30 temporarily fixed to the constricted portion 51b1 of the front protrusion 51b. That is, in the second surface portion 51a2 extending toward the front and lower side as it is separated from the front protrusion 51b, the standing wall 51d is provided at a portion corresponding to the clip 30 temporarily fixed to the constricted portion 51b1, so the standing wall upper surface portion 51a21. The foamed urethane resin raw material M2 can be suspended. Accordingly, the foamed urethane resin material M2 injected into the standing wall upper surface portion 51a21 is expanded upward without delaying the downward expansion of the foamed urethane resin material M1 injected into the first surface portion 51a1, and the front protrusion 51b. It is possible to reduce the deviation of the arrival time to.

  Further, the vertical height from the lower cavity surface 51a of the standing wall 51d is set to 3 to 15 mm, which is about 2/5 of the vertical height from the lower cavity surface 51a of the front convex strip 51b. Thus, the depth of the curved groove 16 formed in the cushion pad 1 by the standing wall 51d becomes shallow and difficult to open, so that the presence of the curved groove 16 can be made difficult to feel through the cushion cover 2. Further, the front ridge 51b is formed in a substantially inverted U shape whose cross section opens downward, and the clip 30 is a direction perpendicular to the longitudinal direction of the front ridge 51b when temporarily fixed to the constricted portion 51b1. And a pair of standing wall portions 32a and a pair of locking claws 32b that engage with the constricted portion 51b1. Thus, the substrate portion 31 is disposed in the cushion pad 1 on the bottom portion 14 a of the front lateral groove 14 over a dimension longer than the width in the direction perpendicular to the longitudinal direction of the front lateral groove 14. Thereby, the clip 30 can be strongly held by the cushion pad 1.

  As mentioned above, although specific embodiment was described, this invention is not limited to those structures, A various change, addition, and deletion are possible in the range which does not change the summary of this invention. For example, the following can be mentioned.

  1. In the above-described embodiment, the shape of the standing wall 51d is formed in a substantially U shape with the opening side facing the front protruding line 51b in a top view and extends upward. However, the present invention is not limited to this, and it may be formed in a substantially U shape by combining straight lines such as a substantially V shape or a part of a polygon, instead of a smooth curved shape in a top view. Furthermore, the degree of the U-shaped curve includes from shallow to deep.

  2. In the above embodiment, the present invention is applied to the cushion pad 1 for an automobile seat. However, the present invention may be applied to a back pad for an automobile seat, or may be applied to an airplane, a ship, a train, etc. You may apply to a pad.

1 Cushion pad (seat cushion material)
2 Cushion cover (seat cover)
14 Front lateral groove (hanging groove)
14a Bottom 30 clip (locking member)
31 Substrate part 32a A pair of standing wall parts (a pair of engaging projections)
32b A pair of locking claws (a pair of engaging projections)
40 Suspender (part of seat cover)
50 Urethane foam mold (mold)
51 Lower mold 51a Lower cavity surface 51b Front projection (projection)
51d Standing wall 51a21 Standing wall upper surface portion 51b1 Constriction portion 51a1 First surface portion 51a2 Second surface portion 52 Upper mold 52a Upper cavity surface 53 Cavity M Foamed urethane resin material M1 Foamed urethane resin material M2 Foamed urethane resin material M3 Foamed urethane resin material SC Seat cushion

Claims (6)

A method for producing a seat cushion material made of foamed resin having a suspension groove in which a locking member that pulls and locks a part of the seat cover is disposed at the bottom,
The seat cushion material forming die includes a lower mold having a lower cavity surface corresponding to the shape of the seat cushion material on the seating surface side, and an upper cavity surface corresponding to the shape opposite to the seat cushion material of the seat cushion material. An upper mold having,
On the lower cavity surface of the lower mold, the hanging groove is formed, and a convex strip provided with a temporary fixing portion capable of temporarily fixing the locking member at a predetermined position on the top is formed by extending upward. Has been
A first surface portion is formed on one side of the lower cavity surface in the longitudinal direction of the ridge so as to extend horizontally or upward as it is separated from the ridge.
On the other side in the longitudinal direction of the ridges on the lower cavity surface, a second surface portion is formed extending downward as being separated from the ridges,
A portion corresponding to the temporary fixing portion of the second surface portion is provided with a standing wall that is formed in a substantially U shape with the opening side facing the ridge in a top view and extends upward,
A method of manufacturing a seat cushion material, in which a foamed resin material is injected onto the first surface portion of the lower mold and the second surface portion including the protruding stripe side of the standing wall to close the upper mold and perform foam molding.   2. The seat cushion material according to claim 1, wherein the vertical height of the upright wall from the lower cavity surface is set to about 2/5 of the vertical height of the ridge from the lower cavity surface. Production method. In Claim 1 or Claim 2, the above-mentioned ridge is formed in a substantially inverted U shape whose cross section opens downward.
The locking member has a flat plate-like substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge when temporarily fixed to the temporary fixing portion, and a lower portion with a predetermined distance from the substrate portion. And a pair of engaging protrusions extending toward the engagement with the temporary fixing portion of the ridge. A foaming mold for manufacturing a seat cushion material made of foamed resin having a hanging groove in which a locking member that pulls and locks a part of the seat cover is disposed at the bottom,
A lower mold having a lower cavity surface corresponding to the shape on the seating surface side of the seat cushion material, and an upper mold having an upper cavity surface corresponding to the shape opposite to the seating surface of the seat cushion material,
On the lower cavity surface of the lower mold, the hanging groove is formed, and a convex strip provided with a temporary fixing portion capable of temporarily fixing the locking member at a predetermined position on the top is formed by extending upward. Has been
A first surface portion is formed on one side of the lower cavity surface in the longitudinal direction of the ridge so as to extend horizontally or upward as it is separated from the ridge.
On the other side in the longitudinal direction of the ridges on the lower cavity surface, a second surface portion is formed extending downward as being separated from the ridges,
A portion corresponding to the temporary fixing portion of the second surface portion is provided with a standing wall that is formed in a substantially U shape with the opening side facing the ridge in a top view and extends upward,
A foaming mold for manufacturing a seat cushion material, wherein the first surface part of the lower mold and the second surface part including the ridge side of the standing wall are portions into which a foamed resin material is injected.   5. The seat cushion material according to claim 4, wherein the vertical height of the standing wall from the lower cavity surface is set to about 2/5 of the vertical height of the convex stripe from the lower cavity surface. Foam mold for manufacturing. In Claim 4 or Claim 5, the above-mentioned ridge is formed in a substantially inverted U shape whose transverse section opens downward.
The locking member has a flat plate-like substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge when temporarily fixed to the temporary fixing portion, and downwards at a predetermined interval from the substrate portion. A foaming mold for manufacturing a seat cushion material, comprising: a pair of engaging protrusions extending and engaging with the temporary fixing portions of the ridges.

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