JP2020090080A - Porous structure, manufacturing method of porous structure, data for 3d molding, and cushion material for seat - Google Patents

Abstract

To provide a porous structure capable of enhancing durability and/or adhesiveness with other members, a manufacturing method for easily manufacturing the porous structure, data for 3D molding used in manufacturing the porous structure by the manufacturing method, and a robust seat by adhering the porous structure to a sheet body with high adhesive force.SOLUTION: The porous structure 1 is a porous structure 1 constituted by a resin or a rubber having flexibility, and has a skeleton part 2 dividing a plurality of cell holes C and a skin part 6 integrally formed with the skeleton part 2 in at least a part of outside of the skeleton part 2 and of which at least a part of outside is a surface.SELECTED DRAWING: Figure 1

Description

The present invention relates to a porous structure, a method for manufacturing a porous structure, 3D modeling data, and a cushion material for a seat.

BACKGROUND ART Conventionally, a cushioning porous structure (for example, urethane foam) has been manufactured through a process of foaming by a chemical reaction in, for example, mold molding (for example, Patent Document 1).

JP, 2016-44292, A

However, the porous structure manufactured as described above may be difficult to adhere to other members on the outside of the porous structure.

Therefore, the present invention can improve the adhesiveness to other members, a porous structure, a porous structure can be easily obtained, a porous structure manufacturing method and 3D modeling data, and An object of the present invention is to provide a cushion material for a seat, in which a porous structure is adhered to a seat body with high adhesive force.

The porous structure of the present invention,
A porous structure made of a flexible resin or rubber,
A skeleton part that defines a plurality of cell holes,
At least a part of the outer side of the skeleton, integrally formed with the skeleton so as to block at least a part of the plurality of cell holes, at least a part of the outer side is a surface, a skin portion,
Equipped with.
According to the porous structure of the present invention, the adhesiveness with other members can be improved.

In the porous structure of the present invention,
The porous structure has a top surface, a bottom surface and side surfaces,
It is preferable that the surface of the skin portion is included in at least one of the top surface, the bottom surface, and the side surface.
Thereby, the adhesiveness with other members can be further improved.

In the porous structure of the present invention,
It is preferable that the surface of the skin portion is continuously formed from the top surface to the side surface and/or from the bottom surface to the side surface.
Thereby, the adhesiveness with other members can be further improved.

In the porous structure of the present invention,
The skin portion comprises a smooth portion in which the surface is formed, and a through hole that is partitioned by the smooth portion and penetrates the skin portion,
It is preferable that the ratio of the total area of the surface to the surface area of the skin portion is 8% or more.
This can further improve the adhesiveness with other members.

In the porous structure of the present invention,
The skin portion has a plurality of through holes,
In a surface view seen from the direction facing the surface of the skin portion, the plurality of through holes, the opening shape to the outer surface of each is circular or oval, the surface of the skin portion is a lattice. It is preferable that they are arranged in a continuous manner.
Thereby, the air permeability of the porous structure can be further improved.

In the porous structure of the present invention,
The skeleton is
Multiple bones,
A plurality of joints, which respectively join the ends of the plurality of bones,
It consists of
The skeleton portion has a first cell dividing portion that divides the first cell hole inside,
The first cell partition portion has a plurality of first annular portions each configured in an annular shape,
The plurality of first annular portions are connected to each other so that the first virtual surfaces defined by the inner peripheral side edge portions do not intersect with each other,
The first cell holes are partitioned by the plurality of first annular portions and the plurality of first virtual surfaces that are partitioned by the plurality of first annular portions, respectively,
It is preferable that the first annular portion is composed of a plurality of the bone portions and a plurality of the coupling portions.
This improves the characteristics of the porous structure as a cushion material.

In the porous structure of the present invention,
The porous structure is preferably formed by a 3D printer.
This facilitates the production of the porous structure. Further, the structure of the porous structure corresponding to various required characteristics can be realized simply and as expected.

The manufacturing method of the porous structure of the present invention,
The above-mentioned porous structure is manufactured using a 3D printer.
According to the method for manufacturing a porous structure of the present invention, it is possible to easily obtain a porous structure capable of improving the adhesiveness with other members.

The data for 3D modeling of the present invention is
3D modeling data read by the control unit of the 3D printer when the modeling unit of the 3D printer performs modeling,
The control unit is configured to cause the modeling unit to model the above-described porous structure.
According to the 3D modeling data of the present invention, it is possible to easily obtain a porous structure capable of improving the adhesiveness with other members by a 3D printer.

The cushion material for the seat of the present invention,
Seat body,
The above-mentioned porosity formed by using a 3D printer in which holes are formed in the sheet body, and at least a part of the surface of the skin portion is adhered to the sheet body. Quality structure,
Equipped with.
According to the cushion material for a seat of the present invention, the porous structure is adhered to the seat body with a high adhesive force.

In the cushion material for the seat of the present invention,
The cushion material for the seat is preferably a vehicle seat pad.
Thereby, the porous structure can be adhered to the sheet body with high adhesive force.

ADVANTAGE OF THE INVENTION According to this invention, the porous structure which can improve adhesiveness with another member, the said porous structure can be easily obtained, the manufacturing method of a porous structure, and 3D modeling data, and It is possible to provide a cushion material for a seat, in which the porous structure is adhered to the seat body with a high adhesive force.

It is an appearance perspective view of the porous structure concerning one embodiment of the present invention. It is sectional drawing which shows a mode when a part of porous structure of FIG. 1 is seen from the direction of the arrow C of FIGS. It is sectional drawing which shows a mode when a part of porous structure of FIG. 1 is seen from the direction of the arrow A of FIG. 2, FIG. 4, and FIG. FIG. 6 is a perspective view showing a state in which the skeleton portion of the porous structure of FIG. 1 is viewed from the direction of the arrow D in FIGS. 2, 3, and 5. It is a perspective view which shows a mode when the skeleton part of the porous structure of FIG. 1 is seen from the direction of the arrow B of FIG. 3 and FIG. FIG. 6 is a perspective view showing a state where the unit portion of the skeleton portion of the porous structure of FIG. 1 is viewed from the direction of the arrow D in FIGS. 2, 3, and 5. It is a perspective view which shows a mode when a part of unit part of the skeleton part of the porous structure of FIG. 6 is expanded and seen. FIG. 7 is a perspective view showing a state of the unit portion of the skeleton portion of the porous structure of FIG. 6 as viewed from the direction of the arrow E in FIG. 6. It is the same drawing as FIG. 8, and is a drawing different from FIG. 8 only in some symbols and broken lines/chain lines. FIG. 7 is a perspective view showing a state where the unit part of the skeleton part of the porous structure of FIG. 6 is viewed from the direction of the arrow F in FIG. 6. It is the same drawing as FIG. 10, and is a drawing different from FIG. 10 only in some symbols and broken lines/chain lines. 12(a) is a perspective view showing a bone part of the porous structure of FIG. 2 in a state where no external force is applied, and FIG. 12(b) is a diagram in which a external force is applied in FIG. 12(a). It is a perspective view which shows the bone part. FIG. 10 is a drawing corresponding to FIG. 9, and is a drawing for explaining a skeleton part of a porous structure according to a first modified example of the present invention. 10 is a drawing corresponding to FIG. 9, and is a drawing for explaining a skeleton part of a porous structure according to a second modification of the present invention. FIG. 10 is a drawing corresponding to FIG. 9, and is a drawing for explaining a skeleton part of a porous structure according to a third modified example of the present invention. It is a perspective view showing a cushioning material for seats provided with a porous structure concerning one embodiment of the present invention. It is a perspective view which shows in detail the main pad part and side pad part in the cushioning material for seats of FIG. FIG. 18 is a perspective view showing the seat body in the main pad portion of FIG. 17. FIG. 19 is a top view showing the seat body of FIG. 18. It is an AA sectional view of the seat main body of FIG. It is a BB sectional view of the seat body of FIG. It is a perspective view which shows the loading body in the main pad part of FIG. It is CC sectional drawing of the porous structure of FIG. It is DD sectional drawing of the porous structure of FIG. FIG. 23 is a perspective view showing a modified example of the skin portion of the porous structure in the main pad portion of FIG. 22. 6 is a view for explaining a method of manufacturing a porous structure of a cushion material for a seat according to an embodiment of the present invention.

Hereinafter, embodiments of a porous structure, a method for manufacturing a porous structure, 3D modeling data, and a cushion material for a seat according to the present invention will be described with reference to the drawings.
The same reference numerals are given to common constituent elements in each drawing.
Further, in FIGS. 1 to 11 and FIGS. 13 to 15, the orientation of the XYZ orthogonal coordinate system fixed to the porous structure is displayed in order to facilitate understanding of the orientation of the porous structure.

First, a porous structure according to an embodiment of the present invention will be described with reference to FIGS. 1 to 12.
FIG. 1 is an external perspective view of a porous structure 1 according to this embodiment. 2 to 5, portions of the porous structure 1 shown in FIG. 1 that are cut into a rectangular parallelepiped are viewed from different angles. FIG. 2 is a plan view of one surface of the part of the porous structure 1, that is, the part of the porous structure 1 in the direction of the arrow C in FIG. 3 to FIG. From the direction). 3 is a plan view of the surface on the right side in FIG. 2 in the relevant portion of the porous structure 1, that is, the relevant portion of the porous structure 1 is indicated by A in FIG. 2, FIG. 4, and FIG. It is viewed from the direction of the arrow (-Y direction). FIG. 4 is a view of the same part of the porous structure 1 as that of FIG. 2 viewed obliquely from above, that is, the part of the porous structure 1 is indicated by the arrow D in FIG. 2, FIG. 3, and FIG. Looking from the direction. FIG. 5 is a perspective view of the surface of the porous structure 1 on the opposite side of FIGS. 2 and 4, that is, the portion of the porous structure 1 is shown in FIGS. Looking from the direction of the arrow B.

The porous structure 1 of this embodiment is formed by a 3D printer. By manufacturing the porous structure using a 3D printer, the manufacturing is simplified and the intended structure can be obtained, as compared with the case where a conventional foaming step by a chemical reaction is performed. Further, it can be expected that, due to the technical progress of the 3D printer in the future, the manufacturing by the 3D printer can be realized in a shorter time and at a lower cost in the future.
In the example shown in FIG. 1, the three-dimensional shape of the porous structure 1 is a rectangular parallelepiped. However, the three-dimensional shape of the porous structure 1 is not limited to a rectangular parallelepiped, and may be any shape such as a sphere.
The porous structure 1 is made of a flexible resin or rubber. Further, the porous structure 1 has a plurality of skeletons 2 forming the skeleton of the porous structure 1, a large number of cell holes C defined by the skeletons 2, and at least a part of the outside of the skeletons 2. A skin portion 6 is formed integrally with the skeleton portion 2 so as to close at least a part of the cell hole, and at least a part of the outer surface is a surface.

The skeleton portion 2 exists over the entire porous structure 1 and is made of a flexible resin or rubber. In this example, the portion of the porous structure 1 other than the skeleton portion 2 is a void.
Here, the "flexible resin" refers to a resin that can be deformed when an external force is applied, and for example, an elastomeric resin is preferable, polyurethane is more preferable, and soft polyurethane is It is more preferable. Examples of rubber include natural rubber and synthetic rubber. Since the porous structure 1 is made of a flexible resin or rubber, it can be compressed/restored and deformed according to the addition/release of an external force, and can have a cushioning property.
From the viewpoint of ease of manufacturing with a 3D printer, it is preferable that the porous structure 1 is made of a flexible resin rather than rubber. ..

The skeleton part 2 of the porous structure 1 of the present embodiment has a configuration in which a plurality of unit parts U each of which is a cube are integrally connected in each of the X, Y, and Z directions. 2 to 5 of the skeleton portion 2 of the porous structure 1 are arranged in the Z direction, three in the Y direction, and two in the X direction, for a total of 18 unit portions. It consists of U. In this example, the configuration, size, and orientation of each unit U that constitutes the porous structure 1 are the same. For convenience, in FIGS. 2 to 5, only one unit U is colored in a darker gray color than the other unit U, and in FIGS. 1 and 2, it is further colored in a dark gray color. The outer edge of the unit U is indicated by a dotted line.
When the outer edge (outer contour) of each unit U of the porous structure 1 is a cube as in this example, it is possible to obtain equal mechanical properties in the XYZ directions.
The outer edge (outer contour) of the unit portion U may be a rectangular parallelepiped other than a cube or another shape. Further, the configuration and/or the size of each unit U constituting the porous structure 1 may not be completely the same, and may be slightly different individually. When the outer edge (outer contour) of each unit U of the porous structure 1 forms a rectangular parallelepiped other than a cube, it is possible to obtain intentional anisotropy as the function of the porous structure 1. For example, when the porous structure 1 is applied to a vehicle seat pad, by making the outer edge (outer contour) of each unit U a rectangular parallelepiped other than a cube, for example, it becomes soft in the Z direction (the direction in which a person sits). It is possible to improve the riding comfort.

6 to 11 show one unit U alone. 6 is a view of the unit portion U from almost the same direction as that of FIG. 3, that is, the unit portion U is viewed from the direction of the arrow D of FIGS. 1 to 3 and 5. FIG. 7 is an enlarged view of a part of FIG. 8 and 9 are the same drawings, and the portion of the unit U on the same side as FIG. 6 is viewed from below, that is, the unit U is viewed from the direction of the arrow E in FIGS. 4 and 6. I'm watching. 8 and 9 are different only in that different broken lines and chain lines are provided for the sake of easy viewing of the drawings. 10 and 11 are the same drawings, and the portion of the unit portion U on the opposite side of FIG. 6 is viewed from above, that is, the unit portion U is viewed from the direction of the arrow F in FIGS. 5 and 6. I'm watching. 10 and 11 are different only in that they are provided with different broken lines and chain lines for the sake of easy viewing of the drawings. For reference, the arrows A, B, and C in FIGS. 2 to 5 are also shown in FIGS. 6 and 8 to 11.

As shown in FIGS. 1 to 11, the skeleton portion 2 of the porous structure 1 is composed of a plurality of bone portions 2B and a plurality of joint portions 2J, and the skeleton portion 2 is integrally configured as a whole. Has been done. In this example, each skeleton 2B has a columnar shape, and in the present example, each skeleton 2B extends linearly. Each of the coupling portions 2J is located at a position where the end portions 2Be of the plurality of bone portions 2B (two to six in the illustrated example) extending in mutually different directions are adjacent to each other, and the end portions 2Be are connected to each other. Are joined together.
In FIGS. 7, 8 and 10, a skeleton line O of the skeleton portion 2 is shown in a part of the porous structure 1. The skeleton line O of the skeleton portion 2 includes the skeleton line O of each bone portion 2B and the skeleton line O of each joint portion 2J. The skeleton line O of the bone portion 2B is the center axis line of the bone portion 2B, and includes the center axis line of the constant bone portion 2B1 and the center axis line of the bone changing portion 2B2 described later. The skeleton line O of the joint portion 2J is an extended line portion formed by smoothly extending the central axis lines of the bone portions 2B joined to the joint portion 2J into the joint portion 2J and joining them.
The extending direction of the bone part 2B is the extending direction of the skeleton line O of the bone part 2B (a part of the skeleton line O corresponding to the bone part 2B. The same applies hereinafter).
Since the porous structure 1 is provided with the skeleton portion 2 over the whole, it is possible to perform compression/restoration deformation according to addition/release of an external force while ensuring air permeability, and therefore, the characteristic as a cushioning material is obtained. Get better Further, the structure of the porous structure 1 is simplified, and it becomes easy to perform modeling with a 3D printer.
In addition, a part or all of the bone parts 2B of the bone parts 2B constituting the skeleton part 2 may extend while curving. In this case, since a part or all of the bone portion 2B is curved, a rapid change in shape of the bone portion 2B and thus the porous structure 1 is prevented when a load is input, and local buckling is suppressed. be able to.
Further, in each of the drawings, each edge portion of the skeleton portion 2 (side portion where a pair of adjacent surfaces abut each other meet) is angular, but each edge portion of the skeleton portion 2 is smoothly curved. Good.

In this example, the respective bone parts 2B constituting the skeleton part 2 have substantially the same shape and length. However, the shape and/or the length of each bone part 2B that configures the skeleton part 2 may not be the same, and for example, the shape and/or the length of a part of the bone part 2B is not limited to this example. May be different from the other bone portion 2B. In this case, by making the shape and/or the length of the bone portion 2B of a specific portion of the skeleton portion 2 different from that of the other portion, intentionally different mechanical characteristics can be obtained. For example, when the porous structure 1 is applied to a vehicle seat pad as in the example of FIG. 16 described later, the seating surface side (front surface side) of the main pad portion 311 is softened to improve riding comfort, The portion 12 forming the side pad portion 312 can be hardened to obtain a hold feeling.
FIG. 12 shows the bone portion 2B of this example alone. FIG. 12A shows a natural state in which an external force is not applied to the bone portion 2B, and FIG. 12B shows a state in which an external force is applied to the bone portion 2B. FIG. 12 shows the central axis (skeleton line O) of the bone portion 2B.
As shown in FIG. 12A, each bone portion 2B has a constant bone portion 2B1 extending while keeping a constant cross-sectional area, and a cross-sectional area on both sides in the extending direction of the bone constant portion 2B1. It is composed of a pair of bone change portions 2B2 extending from the constant bone portion 2B1 to the joint portion 2J while gradually changing. In the present example, each bone change portion 2B2 extends from the constant bone portion 2B1 to the joint portion 2J while gradually increasing the cross-sectional area. Not limited to this example, the same effect can be obtained even if only a part of the bone parts 2B constituting the skeleton part 2 satisfies this configuration. Further, some or all of the bone parts 2B constituting the skeleton part 2 each have a bone change part 2B2 only at one end of the bone constant part 2B1, and the bone constant part 2B1. The other end may be directly coupled to the coupling portion 2J, and in that case, the same effect can be obtained although there may be a difference in degree.
Here, the cross-sectional areas of the constant bone part 2B1 and the bone change part 2B2 refer to the cross-sectional areas of the cross section of the constant bone part 2B1 and the bone change part 2B2 perpendicular to the skeleton line O, respectively.
In this example, each bone part 2B that constitutes the porous structure 1 is composed of a constant bone part 2B1 and a bone change part 2B2, and the bone change part 2B2 cross-sectional area goes from the constant bone part 2B1 to the joint part 2J. Is gradually increased, so that the bone part 2B has a shape that is narrowed toward the bone constant part 2B1 near the boundary between the constant bone part 2B1 and the bone change part 2B2. Therefore, when an external force is applied, the bone portion 2B is likely to buckle and deform at the constricted portion and the intermediate portion of the bone constant portion 2B1, and the porous structure 1 is likely to be compressed and deformed. As a result, the same behavior and characteristics as those of a general polyurethane foam manufactured through a process of foaming by a chemical reaction can be obtained. Further, this makes the touch feeling on the surface of the porous structure 1 softer. For example, when the porous structure 1 is used as a cushioning material for a seat (such as a vehicle seat pad), the seated person is given a softer feel when seated, particularly at the timing when seating starts. .. Such a soft feel is generally widely preferred, and is also preferred by seated passengers in luxury vehicle seat pads (e.g., seated passengers in the backseat with a driver). It is what is done.

When the bone part 2B has the bone constant part 2B1 in at least a part thereof as in this example, the cross-sectional area A1 of the end 2B21 on one side (preferably both sides) of the bone part 2B (see FIG. The ratio A0/A1 of the cross-sectional area A0 (FIG. 12(a)) of the constant bone part 2B1 to a)) is
0.15≦A0/A1≦2.0
It is preferable that the above condition is satisfied. The ratio A0/A1 is
0.5≦A0/A1≦2.0
It is more preferable to satisfy the following. As a result, the touch feeling on the surface of the porous structure 1 can be made to be a moderate hardness, not too soft and not too hard, as a characteristic of the cushion material for a seat. For example, when the porous structure 1 is used as a cushioning material (seat pad or the like) for a seat, it is necessary to give the seated person a feeling of moderate hardness when seated, especially at the timing when seating starts. Become. The smaller the ratio A0/A1, the softer the touch feeling on the surface of the porous structure 1. When the ratio A0/A1 is less than 0.15, the touch feeling on the surface of the porous structure 1 becomes too soft, which may be unfavorable as the characteristic of the cushion material. When the ratio A0/A1 is more than 2.0, the touch feeling on the surface of the porous structure 1 becomes too hard, which may be unfavorable as the characteristic of the cushion material.
More specifically, in this example, the bone part 2B has a constant bone part 2B1 and a pair of bone changing parts 2B2 continuous on both sides thereof, and each bone changing part 2B2 has a cross-sectional area gradually increasing. While increasing, it extends from the constant bone portion 2B1 to the joint portion 2J, and the ratio A0/A1 is less than 1.0. As a result, the touch feeling on the surface of the porous structure 1 can be made relatively soft as a characteristic of the cushion material, particularly as a characteristic of the cushion material for a seat. Such a soft feel is generally widely preferred, and is also preferred by seated passengers in luxury vehicle seat pads (e.g., seated passengers in the backseat with a driver). It is what is done.
It should be noted that each bone part 2B constituting the skeleton part 2 may satisfy this configuration, or only some bone parts 2B of each bone part 2B constituting the skeleton part 2 satisfy this configuration. In either case, the same effect can be obtained although there may be a difference in degree.

Instead of this example, the bone change portion 2B2 may extend from the constant bone portion 2B1 to the joint portion 2J while gradually reducing the cross-sectional area. In this case, the constant bone portion 2B1 has a larger (thicker) cross-sectional area than the bone change portion 2B2. As a result, when the external force is applied, the bone constant portion 2B1 is less likely to be deformed, and instead, the portion which is relatively easy to buckle becomes the bone change portion 2B2 (particularly, the portion on the joint portion 2J side), which in turn has a porous structure. The body 1 is less likely to be compressed and deformed. Thereby, the touch feeling on the surface of the porous structure 1 becomes harder, and high hardness mechanical properties are obtained. For example, when the porous structure 1 is used as a cushioning material for a seat, the seated person is given a harder feel when seated, particularly at the timing when seating starts. Such a behavior cannot be obtained with a general polyurethane foam manufactured through a process of foaming by a chemical reaction. With such a configuration, it is possible to deal with a user who prefers a hard feel. Such a hard feel is preferred by a seated person in a seat pad of a sports car for performing quick acceleration/deceleration or changing diagonal lines, for example.
When the bone change portion 2B2 extends from the constant bone portion 2B1 to the joint portion 2J while gradually reducing the cross-sectional area, the ratio A0/A1 becomes more than 1.0.
It should be noted that each bone part 2B constituting the skeleton part 2 may satisfy this configuration, or only some bone parts 2B of each bone part 2B constituting the skeleton part 2 satisfy this configuration. In either case, the same effect can be obtained although there may be a difference in degree.

Alternatively, as in the first modified example shown in FIG. 13 by a partial dotted line, the bone part 2B may be composed of only the constant bone part 2B1 without the bone change part 2B2. In this case, the cross-sectional area of the bone part 2 is constant over its entire length. Then, the touch feeling of the surface of the porous structure 1 when an external force is applied becomes medium hardness. With such a configuration, it is possible to cope with a user who prefers a feel of medium hardness. Further, it can be suitably applied to seat pads of all kinds of vehicles such as luxury cars and sports cars.
In this case, the ratio A0/A1 is 1.0.
It should be noted that each bone part 2B constituting the skeleton part 2 may satisfy this configuration, or only some bone parts 2B of each bone part 2B constituting the skeleton part 2 satisfy this configuration. In either case, the same effect can be obtained although there may be a difference in degree.

Returning to the example of FIGS. 1 to 12, in this example, in each bone part 2B that constitutes the skeleton part 2, the constant bone part 2B1 has a smaller cross-sectional area than the bone change part 2B2 and the joint part 2J. More specifically, the cross-sectional area of the constant bone part 2B1 is the cross-sectional area of any part of the bone changing part 2B2 and the connecting part 2J (excluding the boundary part between the constant bone part 2B1 and the bone changing part 2B2). Smaller than. That is, the bone constant portion 2B1 is a portion (thin) having the smallest cross-sectional area in the skeleton portion 2. As a result, similarly to the above, when the external force is applied, the bone constant portion 2B1 is easily deformed, and the porous structure 1 is easily compressed and deformed. Thereby, the touch feeling on the surface of the porous structure 1 becomes softer.
The cross-sectional area of the connecting portion 2J refers to the cross-sectional area of a cross section perpendicular to the skeleton line O of the connecting portion 2J.
Note that, not limited to this example, only a part of the bone parts 2B of the bone parts 2B forming the skeleton part 2 may satisfy this configuration, and in that case, although there may be a difference in degree, The same effect can be obtained.

Similarly, in this example, in each bone portion 2B that constitutes the skeleton portion 2, the constant bone portion 2B1 has a smaller width than the bone change portion 2B2 and the joint portion 2J. More specifically, the width of the constant bone part 2B1 is larger than the width of any part of the bone changing part 2B2 and the connecting part 2J (excluding the boundary part between the constant bone part 2B1 and the bone changing part 2B2). ,small. That is, the constant bone portion 2B1 is the smallest (thin) portion in the skeleton portion 2. Also by this, the bone constant portion 2B1 is easily deformed when an external force is applied, whereby the touch feeling of the surface of the porous structure 1 becomes softer.
The widths of the constant bone portion 2B1, the bone change portion 2B2, and the joint portion 2J are measured along a cross section perpendicular to the skeleton line O of the constant bone portion 2B1, the bone change portion 2B2, and the joint portion 2J, respectively. Refers to the maximum width in the cross section. The skeleton line O of the joining portion 2J is a portion of the skeleton line O corresponding to the joining portion 2J. For reference, FIG. 12A shows the width W0 of the constant bone portion 2B1 and the width W1 of the bone change portion 2B2.
Note that, not limited to this example, only a part of the bone parts 2B of the bone parts 2B forming the skeleton part 2 may satisfy this configuration, and in that case, although there may be a difference in degree, The same effect can be obtained.

In each of the above-mentioned examples, the width W0 (FIG. 12) of the bone constant portion 2B1 is 0.05 mm or more from the viewpoint of the simplification of the structure of the porous structure 1 and the ease of manufacturing the 3D printer. It is preferable that it is, and it is more preferable that it is 0.10 mm or more. When the width W0 is 0.05 mm or more, modeling can be performed with the resolution of a high-performance 3D printer, and when the width W0 is 0.10 mm or more, modeling can be performed with the resolution of a general-purpose 3D printer as well as a high-performance 3D printer.
On the other hand, from the viewpoint of improving the accuracy of the outer edge (outer contour) shape of the porous structure 1, reducing the gap (interval) between the cell holes C, and improving the characteristics of the cushion material, The width W0 (FIG. 12) of the constant bone portion 2B1 is preferably 0.05 mm or more and 2.0 mm or less.
It is preferable that each bone part 2B that constitutes the skeleton part 2 satisfies this configuration, but only some bone parts 2B of each bone part 2B that constitutes the skeleton part 2 satisfy this configuration. In that case, the same effect can be obtained although the degree may be different.

As shown in FIG. 12, in this example, each bone part 2B constituting the skeletal part 2 has a bone change part 2B2 and one or more (three in this example) inclined surfaces 2B23 on its side surface. The inclined surface 2B23 is inclined (inclined at less than 90°) with respect to the extending direction of the bone change portion 2B2, and the width W2 gradually increases from the bone constant portion 2B1 toward the joint portion 2J. Is increasing.
Also by this, when an external force is applied, the bone portion 2B is easily buckled and deformed at the constricted portion near the boundary between the constant bone portion 2B1 and the bone change portion 2B2, and the porous structure 1 is compressed. It becomes easy to deform. Thereby, the touch feeling on the surface of the porous structure 1 becomes softer.
Here, the extending direction of the bone changing portion 2B2 is the extending direction of the central axis (skeleton line O) of the bone changing portion 2B2. The width W2 of the inclined surface 2B23 of the bone changing portion 2B2 refers to the width of the inclined surface 2B23 when measured along a cross section perpendicular to the skeleton line O of the bone changing portion 2B2.
Note that, not limited to this example, only a part of the bone parts 2B of the bone parts 2B forming the skeleton part 2 may satisfy this configuration, and in that case, although there may be a difference in degree, The same effect can be obtained.

In this example, in each bone portion 2B that constitutes the skeleton portion 2, the cross-sectional shape of the constant bone portion 2B1 and the bone change portion 2B2 are equilateral triangles.
This simplifies the structure of the porous structure 1 and facilitates modeling with a 3D printer. Further, it is easy to reproduce the mechanical properties of a general polyurethane foam manufactured through a process of foaming by a chemical reaction. Further, by constructing the bone portion 2B in the columnar shape as described above, the durability of the porous structure 1 can be improved as compared with the case where the bone portion 2B is replaced with a thin film-shaped portion.
The cross-sectional shapes of the constant bone portion 2B1 and the changed bone portion 2B2 are shapes in cross sections perpendicular to the central axis (skeleton line O) of the constant bone portion 2B1 and the changed bone portion 2B2, respectively.
Note that, not limited to this example, only a part of the bone parts 2B of the bone parts 2B forming the skeleton part 2 may satisfy this configuration, and in that case, although there may be a difference in degree, The same effect can be obtained.
In all or some of the bone parts 2B constituting the skeleton part 2, the constant bone part 2B1 and the bone change part 2B2 have polygonal cross-sections other than equilateral triangles (regular triangles). Other than the above, it may be a triangle, a quadrangle, etc.) or a circle (a perfect circle, an ellipse, etc.). Further, the constant bone portion 2B1 and the bone change portion 2B2 may have mutually different cross-sectional shapes.

In each example described in this specification, in the volume VS of the porous structure 1, the ratio of the volume VB occupied by the skeleton portion 2 (VB×100/VS [%]) is 3 to 10%, It is suitable. With this configuration, the reaction force generated in the porous structure 1 when an external force is applied to the porous structure 1, and thus the hardness of the porous structure 1, is used as a cushion material for a seat, and more particularly, A good seat pad for a vehicle can be obtained.
Here, the “volume VS of the porous structure 1 ”means the entire internal space (the volume occupied by the skeleton portion 2 and the film 3 described later) surrounded by the outer edge (outer contour) of the porous structure 1. In this case, the total volume of the membrane 3 and the volume of the voids).
When the materials constituting the porous structure 1 are considered to be the same, the higher the ratio of the volume VB occupied by the skeleton 2 to the volume VS of the porous structure 1, the harder the porous structure 1. Further, the lower the ratio of the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1, the softer the porous structure 1.
From the viewpoint of improving the reaction force generated in the porous structure 1 when an external force is applied to the porous structure 1 and, by extension, the hardness of the porous structure 1 as a cushion material for a seat. Is more preferable when the ratio of the volume VB occupied by the skeleton portion 2 to the volume VS of the porous structure 1 is 4 to 8%.
Any method may be used to adjust the ratio of the volume VB occupied by the skeleton 2 to the volume VS of the porous structure 1, but for example, each unit U of the porous structure 1 may be adjusted. The thickness (cross-sectional area) of part or all of the bone parts 2B forming the skeleton 2, and/or the size of part or all of the joints J forming the skeleton 2 without changing the size of The method of adjusting (cross-sectional area) is mentioned.
As an example thereof, in the second modified example shown in FIG. 14, as shown by a dotted line, the thickness (cross-sectional area) of each bone portion 2B that constitutes the skeleton portion 2 and each joint portion J that constitutes the skeleton portion 2 Of the volume VB of the skeleton portion 2 in the volume VS of the porous structure 1 by increasing the size (cross-sectional area) of the porous structure 1 (example of FIG. 9) shown by the solid line. Is increasing.
When the porous structure 1 is used for a vehicle seat pad, the 25% hardness of the porous structure 1 is preferably 60 to 500N, more preferably 100 to 450N. Here, the 25% hardness (N) of the porous structure 1 is determined by using an Instron type compression tester to compress the porous structure 25% in an environment of 23° C. and relative humidity of 50%. The measured value is obtained by measuring the required load (N).

As shown in FIGS. 2 to 5, in the present embodiment, the porous structure 1 has two types of first cell holes C1 and second cell holes C2 having a diameter smaller than that of the first cell holes C1. It has a cell hole C. In the present example, each cell hole C (first cell hole C1 and second cell hole C2) has a substantially polyhedral shape. More specifically, in this example, the first cell hole C1 has a substantially Kelvin tetrahedron (truncated octahedron) shape. The Kelvin tetrahedron (truncated octahedron) is a polyhedron composed of six regular tetragonal constituent surfaces and eight regular hexagonal constituent surfaces. In this example, the second cell hole C2 has a substantially octahedral shape. However, in the example of the figure, since each bone part 2B has not only the bone constant part 2B1 but also the bone change parts 2B2 on both sides thereof, the shapes of the first cell hole C1 and the second cell hole C2 are , And they are not mathematical (perfect) Kelvin tetrahedrons and octahedrons, respectively. Roughly speaking, the cell holes C forming the porous structure 1 space-fill the inner space surrounded by the outer edge (outer contour) of the porous structure 1 (the gap between the cell holes C ( The intervals are small), and they are arranged with regularity. The second cell holes C2 are arranged so as to fill a slight gap (interval) between the first cell holes C1. However, in this example, as can be seen particularly from FIGS. 5 and 10, a part of the second cell hole C2 is inside the first cell hole C1, that is, the first cell hole C1 and the first cell hole C1. The two-cell hole C2 partially overlaps.
As in this example, by making the shape of a part or all (in this example, all) of the cell pores C of the porous structure 1 substantially polyhedral, the space between the cell pores C constituting the porous structure 1 can be reduced. The gap (interval) can be made smaller, and more cell holes C can be formed inside the porous structure 1. Further, as a result, the behavior of the compressive/restoring deformation of the porous structure 1 depending on the application/release of the external force becomes better as a cushion material for a seat.
The shape of the polyhedron formed by the cell holes C is not limited to this example, and any shape is possible. For example, when the shape of the first cell holes C1 is a tetrahedron, a octahedron or a dodecahedron, it is also suitable from the viewpoint of reducing the gap (interval) between the cell holes C. Further, the shape of some or all of the cell holes C of the porous structure 1 may be a three-dimensional shape other than the substantially polyhedron (for example, a sphere, an ellipsoid, a cylinder, or the like). The porous structure 1 may have only one type of cell hole C (for example, only the first cell hole C1), or may have three or more types of cell holes C. Good. When the shape of the first cell hole C1 is approximately Kelvin tetrahedron (truncated octahedron) as in the present example, compared with other shapes, it is generally manufactured through a process of foaming by a chemical reaction. It is the easiest to reproduce the characteristics of the cushioning material equivalent to conventional polyurethane foam.

In this example, one first cell hole C1 is composed of a total of eight unit parts U, each of which has two arranged in each of the X, Y, and Z directions. In addition, one unit portion U constitutes a part of each of the plurality of first cell holes C1. On the other hand, two second cell holes C2 are arranged per unit unit U.
However, the present invention is not limited to this example, and each cell hole C of the porous structure 1 may be composed of an arbitrary number of unit parts U, and each unit part U is an arbitrary number. The cell hole C may be formed.

As shown in FIGS. 2 to 5, in the present example, the skeleton portion 2 has a plurality of (first cell holes C1) first cell partition portions 21 that partition the first cell holes C1 therein. There is.
As shown in FIG. 2, FIG. 3, FIG. 6, and FIG. 8 to FIG. 11, each first cell partition portion 21 has a plurality (14 in this example) of first annular portions 211. .. Each first annular portion 211 is configured in an annular shape, and each inner peripheral side edge portion 2111 partitions a substantially flat first virtual surface V1. The plurality of first annular portions 211 forming the first cell dividing portion 21 are connected to each other so that the first virtual surfaces V1 divided by the inner peripheral side edge portions 2111 do not intersect with each other.
The first cell holes C1 are partitioned by a plurality of first annular portions 211 that form the first cell partitioning portion 21 and a plurality of first virtual surfaces V1 that are partitioned by the plurality of first annular portions 211, respectively. There is. Generally speaking, the first annular portion 211 is a portion that divides the side of the three-dimensional shape formed by the first cell hole C1, and the first virtual surface V1 is the three-dimensional configuration surface formed by the first cell hole C1. Is the part that divides.
Each of the first annular portions 211 is composed of a plurality of bone portions 2B and a plurality of joint portions 2J that join the end portions 2Be of the plurality of bone portions 2B.
The connecting portion between the pair of first annular portions 211 connected to each other is composed of one bone portion 2B shared by the pair of first annular portions 211 and a pair of joint portions 2J on both sides thereof. ing.
Each of the first virtual planes V1 (however, a second virtual plane V2 which will be described later is also excluded) is formed by a surface on one side of the first virtual plane V1 (the surface of the first virtual plane V1). A part of one first cell hole C1 is partitioned, and a part of another first cell hole C1 is formed by the surface on the other side of the first virtual surface V1 (the back surface of the first virtual surface V1). It is partitioned.
In this example, each first virtual surface V1 is not covered with a film and is open, that is, constitutes an opening. Therefore, the cell holes C are communicated with each other through the first virtual surface V1, and the ventilation between the cell holes C is enabled. Thereby, the air permeability of the porous structure 1 can be improved, and the porous structure 1 can be easily compressed/restored and deformed according to the addition/release of the external force.

As shown in FIG. 2, FIG. 3, and FIG. 6 to FIG. 11, in the present example, each of the plurality (14 in the present example) of the first annular portions 211 forming the first cell partition 21 is one. Alternatively, a plurality (six in this example) of the first small annular portions 211S and one or a plurality (eight in this example) of the first large annular portions 211L are included. Each of the first small annular portions 211S partitions the first small virtual surface V1S by its inner peripheral side edge portion 2111. Each of the first large annular portions 211L defines a first large virtual surface V1L having a larger area than the first small virtual surface V1S by the inner peripheral side edge portion 2111 thereof.
8 and 10 show a skeleton line O of a portion of the unit portion U that constitutes the first cell partition portion 21. As can be seen from FIGS. 8 and 10, in the present example, the skeleton line O of the first large annular portion 211L is a regular hexagon, and accordingly, the first large virtual plane V1L is also a substantially regular hexagon. Is playing. In addition, in the present example, the skeleton line O of the first small annular portion 211S has a regular quadrangular shape, and accordingly, the first small virtual surface V1S also has a substantially regular quadrangular shape. As described above, in this example, the first small virtual plane V1S and the first large virtual plane V1L are different not only in area but also in shape.
Each of the first large annular portions 211L includes a plurality (six in this example) of bone portions 2B and a plurality (six in this example) of connecting the end portions 2Be of the plurality of bone portions 2B. And a connecting portion 2J. Each of the first small annular portions 211S includes a plurality of (four in this example) bone portions 2B and a plurality of (four in this example) connecting the end portions 2Be of the plurality of bone portions 2B. And a connecting portion 2J.
A plurality of first annular portions 211 forming the first cell partitioning portion 21 include the first small annular portion 211S and the first large annular portion 211L having different sizes, thereby forming the porous structure 1. It is possible to further reduce the gap (interval) between the one-cell holes C1. Further, as in this example, when the first small annular portion 211S and the first large annular portion 211L have different shapes, the gap (interval) between the first cell holes C1 forming the porous structure 1 is further reduced. It becomes possible to do.
However, the plurality of first annular portions 211 forming the first cell partition 21 may have the same size and/or shape. When the sizes and shapes of the first annular portions 211 forming the first cell partition 21 are the same, it is possible to obtain the same mechanical characteristics in the respective directions of XYZ.

As in this example, a part or all (all in this example) of the first virtual planes V1 forming the first cell partition portion 21 have a substantially polygonal shape. It is possible to further reduce the distance between the cell holes C forming the porous structure 1. Further, the behavior of the compressive/restoring deformation of the porous structure 1 depending on the addition/release of the external force becomes better as a cushion material for a seat. Moreover, since the shape of the first virtual surface V1 is simple, the manufacturability and the ease of adjusting the characteristics can be improved. In addition, when at least one first virtual surface V1 of the first virtual surfaces V1 forming the porous structure 1 satisfies this configuration, the same effect can be obtained although there may be a difference in degree. can get.
At least one first virtual surface V1 of the first virtual surfaces V1 configuring the porous structure 1 is any substantially polygonal shape other than the substantially regular hexagonal shape and the substantially regular tetragonal shape as in this example. Alternatively, a planar shape other than the substantially polygonal shape (for example, a circle (a perfect circle, an ellipse, etc.)) may be formed. When the shape of the first virtual surface V1 is a circle (a perfect circle, an ellipse, etc.), the shape of the first virtual surface V1 is simple, so that the manufacturability and the ease of adjusting the characteristics can be improved, and Homogeneous mechanical properties are obtained. For example, when the shape of the first virtual surface V1 is an ellipse that is long in the direction substantially perpendicular to the direction in which the load is applied (oblong ellipse), an ellipse that is long in the direction substantially parallel to the direction in which the load is applied (longitudinal) Compared with the case where it is an ellipse), the first annular portion 211 that partitions the first virtual surface V1 and thus the porous structure 1 are more easily deformed (softened) with respect to the input of a load.

As shown in FIGS. 2 to 5, in this example, the skeleton portion 2 has a plurality of second cell partition portions 22 (the number of the second cell holes C2) that partition the second cell holes C2 therein. There is.
As shown in FIG. 2, FIG. 3, and FIG. 6 to FIG. 11 (particularly FIG. 7 ), each second cell partition portion 22 has a plurality (two in this example) of second annular portions 222. ing. Each of the second annular portions 222 is formed in an annular shape, and the inner peripheral side edge portions 2221 partition the substantially flat second virtual surface V2. The respective second annular portions 222 forming the second cell dividing portion 22 are connected to each other so that the second virtual surfaces V2 divided by the respective inner peripheral side edge portions 2221 intersect (orthogonally in this example). There is.
The second cell holes C2 are formed by the inner peripheral side edge portions 2221 of the respective second annular portions forming the second cell partitioning portion 22 and the virtual surface smoothly connecting the inner peripheral side edge portions 2221. , Partitioned.
FIG. 7 shows a skeleton line O of a portion of the unit portion U that constitutes the second cell partition portion 22. As can be seen from FIG. 7, in the present example, the skeleton line O of each of the second annular portions 222 forming the second cell partitioning portion 22 is a regular tetragon, and accordingly, the second virtual surface is formed. V2 also has a substantially regular square shape.
Each of the second annular portions 222 includes a plurality of (four in this example) bone parts 2B and a plurality (four in this example) of connecting the end parts 2Be of the plurality of bone parts 2B. And a coupling portion 2J.
In the present example, the connecting portion between the respective second annular portions 222 forming the second cell partitioning portion 22 is configured by the two joining portions J shared by the respective second annular portions 222.
In addition, in the present example, the shapes and areas of the respective second virtual surfaces V2 forming the second cell partition portion 22 are the same as each other.
The shape of each second virtual surface V2 that constitutes the second cell partition 22 is not limited to this example, and any substantially polygonal shape other than the substantially regular quadrangle, or a planar shape other than the substantially polygonal shape (for example, , Circles (perfect circles, ellipses, etc.) may be formed. When the shape of the second virtual surface V2 is a substantially polygonal shape or a circle (a perfect circle, an ellipse, etc.), the shape of the second virtual surface V2 is simple, so that the manufacturability and the ease of adjusting the characteristics are improved. it can. For example, when the shape of the second virtual surface V2 is an ellipse that is long in the direction substantially perpendicular to the direction in which the load is applied (oblong ellipse), an ellipse that is long in the direction substantially parallel to the direction in which the load is applied (longitudinal As compared with the case of an ellipse), the second annular portion 222 that partitions the second virtual surface V2, and thus the porous structure 1, is easily deformed (softened) with respect to the input of a load.
As shown in FIG. 7 and FIG. 10, in the present example, one of the two second annular portions 222 forming the second cell partitioning portion 22 is the first annular portion 211 (more specifically, the first annular portion 211). It also constitutes one small annular portion 211S).
In this example, each second virtual surface V2 is not covered with a film and is open, that is, constitutes an opening. Therefore, the cell holes C (particularly, the first cell hole C1 and the second cell hole C2) are communicated with each other through the second virtual surface V2, and the ventilation between the cell holes C is enabled. Thereby, the air permeability of the porous structure 1 can be improved, and the porous structure 1 can be easily compressed/restored and deformed according to the addition/release of the external force.

As shown in FIGS. 1 to 3, the skin portion 6 of the porous structure 1 of this embodiment is formed integrally with the skeleton portion 2. The skin part 6 is formed on at least a part of the outer side of the skeleton part 2 so as to close at least a part of the plurality of cell holes C. In the present embodiment, the skin part 6 is formed integrally with a part or all of the outermost part of the skeleton part 2 and is a continuous surface so as to close part or all of the cell hole C. have. At least a part of the outer surface of the skin 6 is a surface. Here, the “surface” refers to, for example, a surface that is smoothly continuous, and may be a smooth surface having no unevenness or a surface having unevenness. However, when the surface has irregularities, the surface has a surface roughness that can be realized by using a 3D printer, for example, the dimensions (height, depth, width, The surface roughness (diameter, etc.) is 0.1 mm or more, and the height of the convex portions of the irregularities (that is, the depth of the concave portions) is 2 mm or less.
As described above, when the three-dimensional shape of the porous structure 1 is a rectangular parallelepiped, the porous structure 1 includes the top surface 110, the bottom surface 120 and the side surface 130, and the surface of the skin portion 6 is the top surface 110, the bottom surface. It is included in at least one of 120 and side surface 130.
Specifically, the skin portion 6 can include a top surface side skin portion 61, a bottom surface side skin portion 62, and a side surface side skin portion 63.
The surface of the top surface-side skin portion 61 constitutes the top surface 11 of the porous structure 1. The surface of the bottom surface side skin portion 62 constitutes the bottom surface 102 of the porous structure 1. The side surface skin portion 63 constitutes the side surface 13 of the porous structure 1.
Thus, since the skin 6 is formed on at least a part of the outer side of the skeleton 2 so as to close at least a part of the plurality of cell holes C, the porous structure 1 is bonded to another member. When this is done, another member can be adhered to the surface formed by the skin 6. For this reason, the porous structure 1 is bonded to another member in a wider area as compared with the case where another member is bonded to the outside of the skeleton portion 2, so that the adhesiveness can be improved.

The surface of the skin portion 6 is formed continuously from the top surface 110 of the porous structure 1 to the side surface 130. The surface of the skin portion 6 is formed continuously from the bottom surface to the side surface of the porous structure 1.
Specifically, as shown in FIG. 1, the top surface side skin portion 61 and the side surface side skin portion 63 are continuous so that their respective surfaces are continuous. Similarly, the bottom surface side skin portion 62 and the side surface side skin portion 63 are continuous so that their respective surfaces are continuous. Further, the two side surface skin portions 63 whose surfaces are orthogonal to each other are continuous so that the respective surfaces are continuous.
In this way, since it is continuously formed from the top surface 110 to the side surface 130 and continuously from the bottom surface to the side surface, the surface may be interrupted at any end of the top surface, the side surface, and the bottom surface. Also, the adhesiveness to other members can be improved even at the end portion.

As shown in FIGS. 1 to 3, the skin portion 6 is composed of a smooth portion 6A having a surface formed therein, and a through hole 6B defined by the smooth portion 6A and penetrating the skin portion 6. There is. Specifically, the top surface side skin portion 61, the bottom surface side skin portion 62, and the side surface side skin portion 63 in the skin portion 6 are composed of a smooth portion 6A and a through hole 6B, respectively.
The ratio of the total surface area to the surface area of the skin portion 6 is 8% or more, and preferably 80% or less. The ratio of the total surface area to the surface area of the skin portion 6 is 8% or more, and more preferably 50% or less. The surface area of the skin portion 6 is the sum of the total surface area and the total opening area of the through holes 6B.
When the ratio of the total area of the surface to the surface area of the skin portion 6 is 8% or more, the adhesive force when the porous structure 1 is bonded via the adhesive applied to the surface can be improved. Further, when the porous structure 1 is pressed, the pressing force received by the smooth portion 6A becomes large. Therefore, the portion of the skeleton 2 that is directly impacted is reduced, and the possibility that the skeleton 2 is damaged is reduced. Along with this, the durability of the porous structure 1 increases. However, the ratio of the total surface area to the surface area of the skin portion 6 may be less than 8%. In this case, air permeability between the outer side and the inner side of the skin portion 6 in the porous structure 1 can be increased.

Further, for example, the ratio of the surface area of the smooth portion 6A to the surface area of the skin portion 6 in the portion of the top surface side skin portion 61, the bottom surface side skin portion 62, and the side surface side skin portion 63 facing the seated person is the surface area of the smoothed portion 6A facing the seated person. The seated person can sit comfortably by making the air permeability higher by making it lower than the non-exposed portion. Further, when the porous structure 1 is used in an environment where it is likely to receive an external force, the ratio of the surface area of the smooth portion 6A to the surface area of the region of the epidermis 6 that is likely to be subjected to an external force is made higher than other portions. The durability can be increased.

In the present embodiment, the through-hole 6B has a circular or oval shape (in the present embodiment, circular) in the opening shape to the outer surface when viewed from the surface facing the surface of the skin portion 6. .. However, the through hole 6B is not limited to a circular shape or an oval shape in a surface view, and may be a rectangular shape or another shape. The skin portion 6 includes a plurality of through holes 6B, and the plurality of through holes 6B are arranged in a grid pattern in which the surfaces of the skin portion 6 are arranged in a grid pattern in a front view.

In the present embodiment, the porous structure 1 has at least one cell hole C having a diameter of 5 mm or more. This facilitates the production of the porous structure 1 using a 3D printer. If the diameter of each cell hole C of the porous structure 1 is less than 5 mm, the structure of the porous structure 1 becomes too complicated, resulting in three-dimensional shape data (CAD) representing the three-dimensional shape of the porous structure 1. Data, etc.) or 3D modeling data generated based on the 3D shape data may be difficult to generate on a computer, or even if they can be generated, even if they can be generated, 3D modeling data may be generated according to the 3D modeling data. The printer may be difficult to model.
Since the conventional porous structure having a cushioning property was manufactured through the process of foaming by a chemical reaction as described above, the cell hole C having a diameter of 5 mm or more could not be formed. However, the inventor of the present invention has newly found that even when the porous structure has the cell holes C having a diameter of 5 mm or more, the characteristics as a cushioning material can be obtained which are equivalent to the conventional ones. The porous structure having the cell holes C having a diameter of 5 mm or more facilitates the production by the 3D printer.
Further, since the porous structure 1 has the cell holes C having a diameter of 5 mm or more, it becomes easy to improve the air permeability and the easiness of deformation of the porous structure 1.
The larger the diameter of the cell hole C, the easier it is to manufacture the porous structure 1 using a 3D printer, and the easier it is to improve air permeability and deformability. From such a viewpoint, the diameter of at least one cell hole C in the porous structure 1 is more preferably 8 mm or more, and further preferably 10 mm or more.
On the other hand, if the cell pores C of the porous structure 1 are too large, it becomes difficult to form the outer edge (outer contour) of the porous structure 1 neatly (smoothly), and the shape accuracy decreases and the appearance deteriorates. There is a risk. Further, the characteristics as a cushion material may not be sufficiently good. Therefore, from the viewpoint of improving the appearance and the characteristics as a cushion material, the diameter of each cell hole C of the porous structure 1 is preferably less than 30 mm, more preferably 25 mm or less, and further preferably 20 mm or less. Good.
It should be noted that the more the porous structure 1 has the cell pores C satisfying the above numerical range, the more easily the respective effects described above can be obtained. From this point of view, it is preferable that at least the diameter of each of the first cell holes C1 among the plurality of cell holes C constituting the porous structure 1 satisfies the numerical range of at least one of the above. It is more preferable that the diameter of each cell hole C (each first cell hole C1 and each second cell hole C2) that constitutes the porous structure 1 satisfies at least one of the above numerical range. ..
The diameter of the cell hole C refers to the diameter of the circumscribing sphere of the cell hole C when the cell hole C has a shape different from a strict spherical shape as in this example.

If the cell pores C of the porous structure 1 are too small, it becomes difficult to manufacture the porous structure 1 using a 3D printer. From the viewpoint of facilitating the production of the porous structure 1 using the 3D printer, among the cell holes C constituting the porous structure 1, the cell hole C having the smallest diameter (in the present example, the second cell The diameter of the hole C2) is preferably 0.05 mm or more, and more preferably 0.10 mm or more. When the diameter of the cell hole C having the smallest diameter (in this example, the second cell hole C2) is 0.05 mm or more, modeling can be performed with the resolution of a high-performance 3D printer, and when it is 0.10 mm or more, Not only high-performance 3D printers, but also the resolution of general-purpose 3D printers can be used.

As in the third modified example shown in FIG. 15, in the porous structure 1, at least one of the respective first virtual surfaces V1 forming the porous structure 1 may be covered with the film 3. The film 3 is made of the same material as the skeleton portion 2 and is formed integrally with the skeleton portion 2. The membrane 3 brings the two first cell holes C1 sandwiching the first virtual surface V1 into a non-communication state, and thus the air permeability of the porous structure 1 as a whole is lowered. By adjusting the number of the first virtual surfaces V1 forming the porous structure 1 covered with the film 3, the air permeability of the porous structure 1 as a whole can be adjusted, and according to the request. Various breathability levels are feasible. For example, when the porous structure 1 is used for a vehicle seat pad, the air permeability of the porous structure 1 is adjusted to improve the effectiveness of the air conditioner in the vehicle, the stuffiness resistance, and the riding comfort. Can be increased. When the porous structure 1 is used for a vehicle seat pad, each first virtual surface forming the porous structure 1 is improved from the viewpoint of enhancing the effectiveness and stuffiness resistance of the air conditioner in the vehicle and enhancing the riding comfort. It is not preferable that all of V1 are covered with the film 3, in other words, at least one of the respective first virtual surfaces V1 forming the porous structure 1 is not covered with the film 3 and is open. Preferably.
When the porous structure 1 is used for a vehicle seat pad, the air permeability of the porous structure 1 is 100 to 700 cc from the viewpoints of enhancing the effectiveness and stuffiness resistance of the air conditioner in the vehicle and enhancing the riding comfort. /Cm 2 /sec is preferable, 150 to 650 cc/cm 2 /sec is more preferable, and 200 to 600 cc/cm 2 /sec is further preferable. Here, the air permeability (cc/cm2/sec) of the porous structure 1 is to be measured according to JIS K 6400-7. Further, when the porous structure 1 is used for a vehicle seat pad, the resonance magnification of the porous structure 1 is preferably 3 times or more and less than 8 times, and more preferably 3 times or more and 5 times or less. ..
In addition, since the conventional porous structure was manufactured through the process of foaming by a chemical reaction as described above, the membrane in the communication hole that communicates each cell is formed at the intended position and number. It was difficult to do. When the porous structure 1 is manufactured by the 3D printer as in this example, the information on the film 3 is included in advance in the 3D printing data read by the 3D printer to ensure that the desired position is obtained. And the number of the films 3 can be formed.
From the same viewpoint, at least one of the respective first small virtual surfaces V1S forming the porous structure 1 may be covered with the film 3. And/or at least one of the respective first large virtual surfaces V1L forming the porous structure 1 may be covered with the film 3.

Next, the cushion material 300 for a seat will be described with reference to FIG. FIG. 16 is a perspective view schematically showing a cushion material 300 for a seat according to this embodiment. The cushion material 300 for a seat seat of FIG. 16 may constitute a cushion material for a seat sheet of any kind, but it is preferable to configure a cushion material for a vehicle seat, for example, and a seat pad for a vehicle. Is more preferable.
The cushion material 300 for a seat includes a cushion material 301C for seat cushion on which a seated person sits, a cushion material 301B for seat back for supporting the back of the seated person, and a cushion material 301D for headrest. .. In the example of FIG. 16, the headrest cushion material 301D is configured separately from the seatback cushion material 301B, but may be configured integrally with the seatback cushion material 301B.
In this specification, as shown in FIG. 16, “upper”, “lower”, “left”, “right”, “front”, “when viewed from a seated person who is seated on the cushion material 300 for a seat. Each direction of "rear" is simply referred to as "up", "down", "left", "right", "front", "rear", etc.
The seat cushion cushion material 301C includes a cushion pad 310 formed of the porous structure 1. The cushion pad 310 is located on the left and right sides of the main pad portion 311 and the main pad portion 311 configured to mount the buttocks and thighs of the seated person, and rises above the main pad portion 311 to raise the seated person. It has a pair of side pad portions 312 configured to be supported from both left and right sides.
The seat back cushion material 301B includes a back pad 320 formed of the porous structure 1. The back pads 320 are located on the left and right sides of the main pad portion 321 and the main pad portion 321 configured to support the back of the seated person from the rear side, and rise up to the front side of the main pad portion 321 to raise the seated person. It has a pair of side pad portions 322 configured to be supported from both left and right sides.

Here, an example of the main pad portion 311 will be described in detail. As shown in FIG. 17, the main pad portion 311 includes the seat body 7, and a loading body 8 that is formed in the seat body 7 and is loaded in a hole portion 74 described later.
First, an example of the seat body 7 will be described in detail with reference to FIGS.
FIG. 17 is a perspective view showing in detail the main pad portion 311 and the side pad portion 312. FIG. 18 is a perspective view showing the seat body in the main pad portion of FIG. FIG. 19 is a top view showing the seat body 7 of FIG. 20 is a cross-sectional view taken along the line AA of the seat body 7 of FIG. 21 is a cross-sectional view taken along the line BB of the seat body 7 of FIG.
As shown in FIG. 18, the seat body 7 includes a lower butt portion 71, a thigh peripheral edge portion 72, a groove portion 73, a hole portion 74, and a back pad connecting portion 75. The lower buttocks 71, the thigh peripheral portion 72, and the back pad connecting portion 75 are configured by the porous structure 1B for the seat body 7.

The lower buttocks 71 has a substantially flat flat surface facing upward. As shown in FIG. 19, the lower buttocks 71 includes three straight lines located rearward, leftward, and rightward and a gentle frontward position in a top view of the surface on which the seated person sits, as viewed from the seated person side. It has a shape with one forward convex arc-shaped curve as a peripheral edge.
The lower thigh peripheral edge portion 72 is disposed on the front side of the front curve that forms the peripheral edge of the lower hip 71. The lower thigh peripheral portion 72 defines a substantially rectangular hole portion 74 that extends in the up-down direction inside the lower thigh peripheral portion 72. As shown in FIG. 19, the hole 74 may penetrate the seat body 7 in the vertical direction, or may have a concave shape having a bottom surface above or below.
The lower thigh peripheral portion 72 has a shape in which two straight lines that are located on the left side and the right side that face each other and a gentle arc-shaped curve that is located on the rear side and the front side are the peripheral edges. The gentle arcuate curve located rearward on the lower thigh peripheral edge portion 72 is located along the curve forming the peripheral edge of the lower buttocks 71 with a constant interval.
As shown in FIGS. 19 to 20, the lower thigh peripheral portion 72 includes an upper lower thigh peripheral portion (first lower thigh peripheral portion) 721, a lower lower thigh peripheral portion (second lower thigh peripheral portion) 722, And a front lower thigh peripheral edge portion (third lower thigh peripheral edge portion) 723. The upper thigh lower edge 721, the lower thigh lower edge 722, and the front lower thigh edge 723 are integrally configured. The upper thigh peripheral edge portion 721, the lower thigh lower peripheral edge portion 722, and the front lower thigh peripheral edge portion 723 are also configured integrally with the side pad portion 312.
The upper thigh peripheral edge portion 721 and the lower thigh peripheral edge portion 722 are located on the left and right sides and the rear side of the lower thigh peripheral portion 72. The lower thigh lower peripheral edge portion 722 is located below the upper thigh lower peripheral edge portion 721 and protrudes inward from the upper lower thigh peripheral edge portion 721. Specifically, as shown in FIG. 20, the left side 722L of the lower thigh lower peripheral edge portion 722 projects rightward from the left side 721L of the upper lower thigh peripheral edge portion 721, and the right side 722R of the lower lower thigh peripheral edge portion 722 is the upper side. It protrudes leftward from the right side 721R of the thigh lower edge 721. Further, as shown in FIG. 21, the rear side 722B of the lower thigh lower peripheral edge portion 722 projects forward from the rear side 721B of the upper lower thigh peripheral edge portion 721. Thus, the lower thigh lower peripheral edge portion 722 is formed with a main body step surface BS that is a step surface that is continuous with the inner side surface of the upper lower thigh peripheral edge portion 721 and that extends upward.
As shown in FIG. 19, the front lower thigh peripheral edge portion 723 is located on the front side of the entire lower thigh peripheral edge portion 72. As shown in FIG. 20, the upper end portion 723T of the front lower thigh peripheral edge portion 723 is located at the lowest position in the vicinity of the center in the left-right direction, and is located higher toward the left-right direction end portion.

As shown in FIGS. 18 and 19, the groove portion 73 is a groove defined by a rear curve that forms the peripheral edge of the thigh peripheral edge portion 72 and a curve that forms the peripheral edge of the lower hip 71. The groove portion 73 can accommodate a seam margin of the cover that covers the cushion material 300.
The back pad connecting portion 75 is configured to be connected to the bottom lower portion 71, and is configured to be connected to the back pad 320.

Next, with reference to FIGS. 22 to 24, an example of the porous structure 1S that constitutes the loading body 8 included in the main pad portion 311 will be described in detail. 22 is a perspective view showing a loading body in the main pad portion of FIG. FIG. 23 is a cross-sectional view taken along line CC of the porous structure shown in FIG. 24 is a DD cross-sectional view of the porous structure of FIG. The porous structure 1S shown in FIGS. 23 and 24 is omitted in the portion indicated by the dashed line in the left-right direction.
The loading body 8 is composed of the porous structure 1S. The porous structure 1S (hereinafter, simply referred to as “porous structure 1S”) forming the loading body 8 is a porous structure having characteristics different from those of the porous structure 1B for the sheet body 7. The porous structure 1S that constitutes the loading body 8 includes, for example, the skeleton portion 2 and the skin portion 6, similarly to the above-described porous structure 1, and the skin portion 6 includes the smooth portion 6A and the through hole 6B. Have.
FIG. 22 is an external perspective view of the porous structure 1S. FIG. 23 is a sectional view taken along line CC of the porous structure 1S of FIG. FIG. 24 is a DD cross-sectional view of the porous structure 1S of FIG.
The porous structure 1S is formed by a 3D printer. The porous structure 1S includes the skeleton portion 2 and the outer skin portion 6 integrally formed with the skeleton portion 2 on the outermost side of the skeleton portion 2, similarly to the porous structure body 1 described above. The skeleton part 2 and the epidermis part 6 are similar to the skeleton part 2 and the epidermis part 6 of the porous structure 1, and the epidermis part 6 includes the top surface epidermis part 61, the bottom surface side epidermis part 62, and the side surface epidermis. And a part 63. The shape of the porous structure 1S is different from the shape shown in the example of the porous structure 1 described above.

As shown in FIG. 22, the porous structure 1S includes a first portion 1S1 and a second portion 1S2 formed integrally with the first portion 1S1. The second portion 1S2 is configured to protrude from the first portion 1S1 in a direction orthogonal to the sitting direction (downward direction shown in FIG. 1) when the seated person is seated on the cushion material 300 for a seat. .. Specifically, as shown in FIG. 23, the second portion 1S2 is configured to project in the left-right direction from the first portion 1S1. Further, as shown in FIG. 24, the second portion 1S2 is configured to project in the front-rear direction from the first portion 1S1.
In such a porous structure 1S, the side surface-side skin portion 63 formed outside the side surface side of the skeleton portion 2 of the skin portion 6 is located outside the side surface side of the skeleton portion 2 in the first portion 1S1. The first side surface-side skin portion 631 that is formed and the second side surface-side skin portion 632 that is formed outside the side surface side of the skeleton portion 2 in the second portion 1S2 are included. Further, since the second portion 1S2 projects from the first portion 1S1, the second portion 1S2 is configured with a pad step surface PS that faces downward and is a step surface that is continuous with the first portion 1S1. The porous structure 1S is configured such that the pad step surface PS in the second portion 1S2 is along the body step surface BS of the seat body 7.
Further, as shown in FIG. 22, the lower end of the portion projecting forward of the second portion 1S2 is curved so that it is lowest near the center in the left-right direction and becomes higher toward the end portion in the left-right direction. .. The lower end portion of the second projecting portion of the second portion 1S2 is curved so as to follow the curved shape at the upper end of the front thigh lower peripheral edge portion 723, which has already been described with reference to FIG. As a result, the porous structure 1S is arranged in front of the main pad portion 311 and more widely in the vicinity of the center than in the end portion. Therefore, the porous structure 1S having at least a cushioning property is arranged at a portion facing the seated person, and the seated person can comfortably sit.
In addition, the surface of the portion of the side surface skin portion 63 that protrudes forward of the second portion 1S2 forms a curved surface. As a result, when the seated person sits on the cushioning material 300 for a seat in which the porous structure 1S is arranged, the front curved surface of the second portion 1S2 is along the back of the seated person's knees and the back lower leg. Therefore, it is possible to prevent the seated person from hitting the corner of the porous structure 1S.

The length L1 in the left-right direction of the first portion 1S1 shown in FIGS. 22 and 23 is defined by the left and right sides of the lower thigh lower peripheral edge portion 722 shown in FIG. It is substantially the same as the length L2 in the left-right direction. However, the length L1 may be slightly longer than the length L2 in order to press-fit the first portion 1S1 into close contact with the lower thigh lower peripheral edge portion 722. The longitudinal length L3 of the first portion 1S1 shown in FIGS. 22 and 24 is defined by the rear side of the lower thigh lower peripheral edge 722 and the front lower thigh peripheral edge 723 shown in FIG. It is substantially the same as the length L4 of the lower portion of the hole 74 in the front-rear direction. However, the length L3 may be slightly longer than the length L4 in order to press-fit the first portion 1S1 into the hole portion 74 and bring the lower leg thigh peripheral edge portion 722 into close contact with each other.
The length L5 in the left-right direction of the second portion 1S2 shown in FIGS. 22 and 23 is the length in the left-right direction of the upper side of the hole portion 74, which is divided by the left-right sides of the upper thigh lower peripheral edge portion 721 shown in FIG. It is almost the same as L6. However, the length L5 may be slightly longer than the length L6 in order to press-fit the second portion 1S2 into the hole portion 74 and bring it into close contact with the upper thigh peripheral edge portion 721. The length L7 in the front-rear direction of the second portion 1S2 shown in FIGS. 22 and 24 is the length in the front-rear direction between the rear side of the upper thigh lower peripheral edge 721 and the front lower thigh peripheral edge 723 shown in FIG. The length may be substantially the same as the length L8 or may be slightly longer.
The vertical length L9 of the second portion 1S2 shown in FIGS. 23 and 24 is substantially the same as the vertical length L10 of the upper thigh lower peripheral edge portion 721 shown in FIG.
With such a structure, when the porous structure 1S that constitutes the cushioning material 300 for a seat is loaded in the hole 74, the portion of the second portion 1S2 projecting from the first portion 1S1 is caused by the main body step surface BS. It is locked. Thereby, the porous structure 1S is vertically positioned in the hole portion 74 of the sheet body 7. Therefore, the porous structure 1S can be stably arranged on the cushion material 300 for a seat.

The porous structure 1S is loaded in the hole 74 of the seat body 7. The porous structure 1S is arranged in a portion of the cushion material 300 for a seat that faces a seated person. It is preferable that the ratio of the volume of the porous structure 1S to the volume of the cushion material 300 for a seat is 10 to 70%. With such a ratio, it is possible to maintain the robustness while maintaining the air permeability of the cushion material 300 for a seat.
The porous structure 1S is inserted into the hole portion 74 from above the hole portion 74 with the first portion 1S1 facing downward when loading the hole portion 74. As a result, the portion of the second portion 1S2 that projects from the first portion 1S1 is locked by the body step surface BS, and the porous structure 1S can be positioned in the vertical direction in the hole portion 74 of the seat body 7. .. Therefore, since the porous structure 1S is stably arranged, the cushion material 300 for a seat can be easily obtained.

Further, the first side surface side skin portion 631 is fixed in a state of being in contact with the inner side surface of the lower thigh lower peripheral edge portion 722 via an adhesive, whereby the first portion 1S1 is fixed to the lower thigh lower peripheral edge portion 722. It is fixed to the portion 722. In addition, the second side surface-side skin portion 632 is fixed in a state of being in contact with the inner side surface of the upper thigh lower peripheral edge portion 721 via an adhesive, whereby the second portion 1S2 is fixed to the upper lower thigh peripheral edge portion 721. It is fixed. Further, the pad step surface PS is fixed in a state of being in contact with the main body step surface BS of the lower thigh peripheral edge portion 72 via an adhesive, whereby the first portion 1S1 is fixed to the pad step surface PS. There is.
Thereby, the loading body 8 configured by the porous structure 1S has a high adhesive force to the seat body 7 on each of the first side surface-side skin portion 631, the second side surface-side skin portion 632, and the pad step surface PS. It is possible to manufacture the cushioning material 300 for a seat, which can be adhered to the seat and has high robustness.
In the above description, the porous structure 1S and the sheet main body 7 are configured such that the first portion 1S1 is on the lower side and the porous structure 1S is inserted from above the hole 74 to below. However, it is not limited to this. For example, the porous structure 1S and the seat body 7 may be configured such that the porous structure 1S is inserted into the seat body 7 from below.

As shown in FIG. 25, the second side surface skin portion 632 of the porous structure 1S may not have the through hole 6B. As a result, the second side surface skin portion 632 is firmly fixed to the inner wall surface of the hole portion 74 of the seat body 7 via an adhesive in a wider area than in the case where the through hole 6B is provided, and a robust seat seat. The cushion material 300 for use is formed. Although not shown, similarly, the first side surface skin portion 631 of the porous structure 1S may not have the through hole 6B. In this case, similarly, the second side surface-side skin portion 632 can be firmly fixed to the inner wall surface of the hole portion 74 of the seat main body 7 in a wide area with an adhesive. Further, as described above, in the case of a concave shape having a bottom surface on the upper side or the lower side, the bottom surface skin portion 62 or the top surface skin portion 61 that comes into contact with the bottom surface when the loading body 8 is loaded in the hole portion 74 is The through hole 6B may not be provided.

Next, with reference to FIG. 26, a method of manufacturing the seat body 7 and the loading body 8 loaded in the hole portion 74 formed in the seat body 7 according to the embodiment of the present invention will be described. FIG. 26 shows, as an example, a state where the loading body 8 according to the embodiment of the present invention shown in FIGS. 22 to 24 is manufactured by a 3D printer.
First, using a computer, three-dimensional shape data (for example, three-dimensional CAD data) representing the three-dimensional shape of the porous structure 1S forming the loading body 8 is created in advance.
Next, a computer is used to convert the three-dimensional shape data into 3D modeling data 500. The 3D modeling data 500 is read by the control unit 410 of the 3D printer 400 when the modeling unit 420 of the 3D printer 400 performs modeling, and the control unit 410 configures the loading body 8 in the modeling unit 420. The porous structure 1S is configured to be shaped. The 3D modeling data 500 includes, for example, slice data representing the two-dimensional shape of each layer of the porous structure 1S that constitutes the loading body 8.
Next, the 3D printer 400 forms the porous structure 1S that constitutes the loading body 8. The 3D printer 400 may perform modeling using any modeling method such as, for example, a stereolithography method, a powder sintering lamination method, a hot melt lamination method (FDM method), an inkjet method, or the like. FIG. 26 shows a state where modeling is performed by the optical modeling method.
The 3D printer 400 includes, for example, a control unit 410 configured by a CPU and the like, a modeling unit 420 that performs modeling under the control of the control unit 410, and a support base on which a modeled object (that is, the cushion material 301) to be modeled is placed. 430 and a container 440 in which the liquid resin LR, the support 430, and the modeled object are housed. The modeling unit 420 includes a laser irradiator 421 configured to irradiate the ultraviolet laser light LL when the optical modeling method is used as in this example. The container 440 is filled with the liquid resin LR. The liquid resin LR cures when exposed to the ultraviolet laser light LL emitted from the laser irradiator 421, and becomes a flexible resin.
In the thus configured 3D printer 400, first, the control unit 410 reads the 3D modeling data 500, and based on the three-dimensional shape included in the read 3D modeling data 500, the modeling unit 420 receives the ultraviolet laser light. Each layer is sequentially modeled while controlling to irradiate LL.
After the modeling by the 3D printer 400 is completed, the modeled object is taken out from the container 440. As a result, the porous structure 1S as the loading body 8 is finally obtained as a molded article.
When the porous structure 1S is made of resin, the porous structure 1S as a modeled object may be heated in an oven after the modeling by the 3D printer 400 is completed. In that case, since the bonding between the layers forming the porous structure 1S can be strengthened and the anisotropy of the porous structure 1S can be reduced, the characteristics of the porous structure 1S as a cushioning material can be further improved. ..
Further, when the porous structure 1S is made of rubber, the porous structure 1S as a molded article may be vulcanized after the modeling by the 3D printer 400 is completed.

In this way, when the loading body 8 is shaped using the 3D printer, the porous structure 1S is loaded in the hole 74. Before loading the porous structure 1S, an adhesive is applied to the inner side wall of the thigh lower edge portion 72 or the side surface skin portion 63. Then, the porous structure 1 is inserted downward from above the hole 74 with the first portion 1S1 on the lower side. As a result, the portion of the second portion 1S2 that projects from the first portion 1S1 is locked by the main body step surface BS, and the porous structure 1 that constitutes the cushion material 300 for a seat seat has a hole portion of the seat main body 7. Positioned vertically at 74.
Further, the adhesive is cured in a state where the first side surface skin portion 631 is in contact with the inner side surface of the lower thigh lower peripheral edge portion 722 via the adhesive, so that the first portion 1S1 is It is fixed to the portion 722. Further, the adhesive is cured in a state where the second side surface-side skin portion 632 is in contact with the inner side surface of the upper thigh lower peripheral edge portion 721 through the adhesive, so that the second portion 1S2 is moved to the upper lower thigh peripheral edge portion 721. Fixed. Further, the adhesive is hardened in a state where the pad step surface PS is in contact with the main body step surface BS of the thigh lower edge portion 72 via the adhesive, whereby the first portion 1S1 is fixed to the pad step surface PS. .. In this way, the main pad portion 311 in which the loading body 8 configured by the porous structure 1S as shown in FIG. 17 is loaded on the seat body 7 is formed.
By modeling the loading body 8 using a 3D printer, the configuration of the porous structure 1S as the loading body 8 can be easily changed by changing the data for 3D printing. Thereby, the characteristics of the loading body 8 can be easily adjusted. For example, by simply changing the data for 3D modeling, it is possible to easily change the size of each part constituting the skeleton part 2 and the shape and size of the cell hole, or the size of the through hole 6B in the skin part 6, The shape, number, and position can be changed. Therefore, it is possible to form the porous structure 1S whose characteristics are changed by easily changing the structure as described above, the characteristics can be easily adjusted, and the loading body 8 can be realized simply and as intended.
Further, by using such a loading body 8, it is possible to easily obtain the cushion material 300 for a seat, which can easily meet various required characteristics.

INDUSTRIAL APPLICABILITY The porous structure, the method for manufacturing the porous structure, the 3D modeling data, and the cushioning material for a seat of the present invention are more preferably used for a seat and used for a seat for a vehicle. More preferably,

1: Porous structure, 110: Top surface, 120: Bottom surface, 130: Side surface, 1B: Porous structure constituting the sheet body, 1S: Porous structure constituting the loading body, 1S1: First part, 1S2: Second part, 2: Skeleton part, 2B: Bone part, 2Be: End part of bone part, 2B1: Bone constant part, 2B2: Bone change part, 2B21: End part of joint part of bone change part, 2B22: 2B23: inclined surface of bone change part, 2J: joint part, 3: membrane, 11: first part of porous structure, 12: second part of porous structure , 13: third part of porous structure, 21: first cell partition part, 22: second cell partition part, 211: first annular part, 211L: first large annular part, 211S: first small annular part 2111: Inner peripheral edge of the first annular portion 222: Second annular portion 2221: Inner peripheral edge of the second annular portion 301: Cushion material for seat, 301B: Cushion material for seat back , 301C: cushion material for seat cushion, 310: cushion pad, 311: main pad portion, 312: side pad portion, 320: back pad, 321: main pad portion, 322: side pad portion, 340: headrest, 400:3D Printer, 410: control unit, 420: modeling unit, 421: laser irradiator, 430: support, 440: container, LL: ultraviolet laser light, LR: liquid resin, 500: 3D modeling data, 6: skin unit , 61: top surface side skin part, 62: side surface side skin part, 63: bottom surface side skin part, 6A: smooth part, 6B: through hole, 7: seat body, 71: lower part of hip, 72: lower thigh peripheral part, 73: groove part, 74: hole part, 721 upper thigh lower rim part 721: lower thigh lower rim part, 8: loaded body, C: cell hole, C1: first cell hole, C2: second cell hole, O: Skeleton line, U: Unit part of porous structure, V1: first virtual surface, V1L: first large virtual surface, V1S: first small virtual surface, V2: second virtual surface, BS: stepped surface of main body, PS : Pad step surface

Claims (11)

A porous structure made of a flexible resin or rubber,
A skeleton part that defines a plurality of cell holes,
At least a part of the outer side of the skeleton, integrally formed with the skeleton so as to block at least a part of the plurality of cell holes, at least a part of the outer side is a surface, a skin portion,
And a porous structure. The porous structure has a top surface, a bottom surface and side surfaces,
The porous structure according to claim 1, wherein the surface of the skin portion is included in at least one of the top surface, the bottom surface, and the side surface. The porous structure according to claim 2, wherein the surface of the skin portion is continuously formed from the top surface to the side surface and/or from the bottom surface to the side surface. The skin portion comprises a smooth portion in which the surface is formed, and a through hole that is partitioned by the smooth portion and penetrates the skin portion,
The porous structure according to any one of claims 1 to 3, wherein a ratio of a total area of the surface to a surface area of the skin portion is 8% or more. The skin portion has a plurality of through holes,
In a surface view seen from the direction facing the surface of the skin portion, the plurality of through holes, the opening shape to the outer surface of each is circular or oval, the surface of the skin portion is a lattice. The porous structure according to claim 4, wherein the porous structure is arranged so as to be continuous. The skeleton is
Multiple bones,
A plurality of joints, which respectively join the ends of the plurality of bones,
It consists of
The skeleton portion has a first cell dividing portion that divides the first cell hole inside,
The first cell partition portion has a plurality of first annular portions each configured in an annular shape,
The plurality of first annular portions are connected to each other so that the first virtual surfaces defined by the inner peripheral side edge portions do not intersect with each other,
The first cell holes are partitioned by the plurality of first annular portions and the plurality of first virtual surfaces that are partitioned by the plurality of first annular portions, respectively,
The said 1st cyclic|annular part is a porous structure body as described in any one of Claims 1-5 comprised from several said bone|frame parts and several said joint parts. The porous structure according to any one of claims 1 to 6, wherein the porous structure is formed using a 3D printer. A method for producing a porous structure, comprising producing the porous structure according to claim 1 using a 3D printer. 3D modeling data read by the control unit of the 3D printer when the modeling unit of the 3D printer performs modeling,
Data for 3D modeling, wherein the control unit is configured to cause the modeling unit to model the porous structure according to any one of claims 1 to 6. Seat body,
The porous structure according to claim 7, wherein the porous structure is loaded in a hole formed in the sheet body, and at least a part of the surface of the skin portion is bonded to the sheet body.
A cushioning material for seats, which is equipped with. The cushioning material for a seat according to claim 10, wherein the cushioning material for the seat is a vehicle seat pad.