JP2020138634A - Vehicular cushion pad and manufacturing method thereof - Google Patents

Abstract

To provide a vehicular cushion pad and a manufacturing method thereof that eliminates a need for adjustment on a mold side, eliminates an appearance defect that scrapes a first foam molded product, enables interference with an upper mold and the first foam molded product, facilitates setting, and also aims to improve a holding power to the upper mold.SOLUTION: In a vehicular cushion pad in which a second foam molded product 3 in which a seat layer 31 having a contact surface part 311 on a side where a seated occupant comes into contact is laminated on a first foam molded product 2 to be a lower layer is foam molded, the first foam molded product 2 has a smaller density and a higher hardness than the second foam molded product 3, and has a raised part 24 having a side wall surface 241 that is substantially vertical under a vehicle installation of the cushion pad on a part of the back side, and a plurality of protruding bulges 25 are formed on the side wall surface 241 which is substantially vertical of the raised part 24.SELECTED DRAWING: Figure 2

Description

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

In the seats for automobiles and the like, the cushion pads that make up the seats have been made of flexible polyurethane foam molded body u so that comfortable cushioning can be obtained, but in recent years, as a measure to reduce weight, styrofoam has been used as a lower layer for raising. The movement to replace the beaded foam m with the above is in progress (a in FIG. 14). However, the bead foam m undergoes molding shrinkage due to its foam molding, resulting in variations in dimensional accuracy.
The cushion pad P is formed with a flexible polyurethane foam molded body u upside down from the state in which the vehicle is installed. Since the bead foam m is insert-molded, it is set on the upper mold T by using the overhanging portion m1 protruding from the back surface of the bead foam m. However, if it is smaller than the predetermined size, it is used for the overhanging portion m1. The overhanging elevation m18 separates from the upper die dent T1 and falls off (b in FIG. 14). On the other hand, if the overhanging portion m1 is large, a usable portion m19 is formed, which makes it difficult to set the bead foam m on the upper mold T (c in FIG. 14).
For these reasons, several inventions have been proposed to prevent falling off and difficulty in mounting (for example, Patent Document 1).

JP-A-2018-130398

However, in Patent Document 1, the upper mold protrudes from the wall surface of the concave portion sandwiching the convex portion which is the overhanging portion of the bead foam (first foam molded product in the present invention) so as to interfere with the convex portion. It has a metal protrusion. Therefore, if the degree of interference is even a little large, it will not function, the mold needs to be tuned, and the dimensions of the hard protrusions need to be adjusted. Further, even if the bead foam can be set on the upper mold, there is a problem that the side surface of the bead foam is scraped at the protrusion.

The present invention solves the above-mentioned problems, does not require adjustment on the mold side, eliminates an appearance defect that scrapes the first foamed molded product, and also has an upper mold of the first foamed molded product. It is an object of the present invention to provide a cushion pad for a vehicle and a method for manufacturing the same, which enables interference to facilitate setting and also improves the holding force to an upper mold.

In order to achieve the above object, the gist of the invention according to claim 1 is that the seat layer having the contact surface portion on the side where the seated occupant comes into contact is laminated on the first foam molded body which is the lower layer. (Ii) In a vehicle cushion pad in which a foam molded product is foam-molded, the first foam molded product has a smaller density and a higher hardness than the second foam molded product, and a cushion pad is provided on a part of the back surface side thereof. In the vehicle installation, a plurality of protruding bulges are formed on the side wall surface which has a side wall surface which is substantially vertical and has a raised portion, and which is substantially vertical to the raised portion. It is in the cushion pad for vehicles characterized by. The vehicle cushion pad according to the second aspect of the present invention is characterized in that, according to the first aspect, a plurality of the bulges formed into vertical stripes in the vertical direction are provided in the circumferential direction of the side wall surface. The vehicle cushion pad according to the third aspect of the present invention is characterized in that, according to the first or second aspect, the bulge is formed so that its cross-sectional shape is reduced downward. The vehicle cushion pad according to claim 4, wherein the raised portions are formed in pairs separated in the vehicle width direction, and both are arranged on both outer sides in the vehicle width direction, and both raised portions are formed. It is characterized in that the bulge is exposed and formed on the side wall surfaces facing each other in the portion. The vehicle cushion pad according to the fifth aspect of the present invention is characterized in that, according to the first to fourth aspects, the raised portion is set to a height protruding downward from the floor surface of the vehicle body when installed in the vehicle. .. In the vehicle cushion pad according to the sixth aspect of the present invention, in the first to fifth aspects, the outer peripheral portion of the back surface of the first foam molded product is left, a lower recessed area is provided inside the cushion pad, and the depressed bottom of the depressed area is provided. A part of the back surface of the first foamed molded product is raised to form the raised portion.
The gist of the invention according to claim 7 is to foam-mold a second foam-molded article in which a seat layer having a contact surface portion on a side where a seated occupant abuts is laminated on a first foam-molded article to be a lower layer. In the method for manufacturing a cushion pad for a vehicle, the first foam molded product has a smaller density and a higher hardness than the second foam molded product, and is substantially on the back surface side when the cushion pad is installed on the vehicle. A raised portion having a vertical side wall surface is formed, and a plurality of ridge bulges are formed on the side wall surface that is substantially vertical to the raised portion, while the raised portion is formed on the upper cavity surface. A corresponding concave hole is formed, the back surface side of the first foamed molded product is turned upward, and the raised portion is fitted into the concave hole while compressing and deforming the bulge, and the first foamed molded product is placed in the upper mold. A method for producing a cushion pad for a vehicle, which comprises setting, then injecting a foamed raw material for a second foam molded product onto a lower mold cavity surface, closing the mold, and then foam molding the second foam molded product. It is in. The method for manufacturing a cushion pad for a vehicle, which is the invention of claim 8, is characterized in that, in claim 7, a plurality of the bulges formed into vertical stripes in the vertical direction are formed on the side wall surface. The method for manufacturing a cushion pad for a vehicle, which is the invention of claim 9, is characterized in that, in claim 7 or 8, the cross-sectional shape of the bulge is reduced downward. The method for manufacturing a vehicle cushion pad according to claim 10, wherein a pair of raised portions are formed apart from each other in the vehicle width direction, and both are arranged on both outer sides in the vehicle width direction. It is characterized in that the bulge is formed on the side wall surfaces facing each other in both raised portions.

In the vehicle cushion pad of the present invention and the method for manufacturing the same, although the bulge provided on the side wall surface of the raised portion interferes with the upper mold, the first foam molded body is formed with a protruding bulge that can be compressively deformed. The bulge is compression-deformed so that the first foamed molded product can be easily set on the upper mold by increasing the holding force, and exhibits an excellent effect.

It is an overall perspective view of the cushion pad for a vehicle of this invention and one form of the manufacturing method thereof. It is explanatory cross-sectional view which cut | cut the cushion pad of FIG. 1 in the vehicle width direction. It is a perspective view which looked at the 1st foam molded article of FIG. 1 from the back surface side. It is a perspective view which looked at the 1st foam molded article of another aspect alternative to FIG. 3 from the back surface side. It is explanatory cross-sectional view of the cushion pad of another aspect alternative to FIG. (A) is a cross-sectional view around the raised portion of FIG. 4, and (b) to (d) are other aspects instead of (a). FIG. 5 is an explanatory cross-sectional view of a state in which the first foam molded product of FIG. 5 is set in the upper mold. (A) is a partially enlarged view in which the first foam molded product is set in the upper mold, and (b) is a sectional view taken along line VIII-VIII of (a). It is explanatory cross-sectional view which injects a foaming raw material after FIG. It is explanatory drawing of the mold closing. It is explanatory cross-sectional view which foam-molded the second foam-molded article. It is another aspect diagram which replaces FIG. It is another aspect diagram which replaces FIG. (A) is a perspective view of a conventional cushion pad, and (b) and (c) are explanatory cross-sectional views showing a defect when the first foam molded product of (a) is set in the upper mold.

Hereinafter, the vehicle cushion pad (hereinafter, also simply referred to as “cushion pad”) and the manufacturing method thereof according to the present invention will be described in detail.
1 to 13 are one form of the cushion pad of the present invention and a method for manufacturing the same, FIG. 1 is a perspective view of the cushion pad, FIG. 2 is a sectional view of FIG. 1, and FIG. 3 is a first foam molded product of FIG. Back side perspective views, FIGS. 4 and 5 are alternative views of FIGS. 3 and 2, FIG. 6 is a cross-sectional view around the raised portion of FIG. 4, and (b) to (d) are (a). 7 is a cross-sectional view in which the first foamed molded product of FIG. 5 is set in the upper mold, and FIG. 8 is a partially enlarged view in which the first foamed molded product of FIG. 5 is set in the upper mold. ) Is a sectional view taken along line VIII-VIII of (a), FIG. 9 is a sectional view in which a foamed raw material is injected, FIG. 10 is a sectional view of closing the mold, and FIG. FIG. 13 is a cross-sectional view that replaces FIGS. 7 and 11. Each drawing highlights the main parts of the invention to make the drawings easier to understand, and simplifies or omits parts not directly related to the present invention.

(1) Cushion Pad for Vehicle The cushion pad 1 for a vehicle is a cushion pad that supports and supports the lower body of a seated occupant. It is applied to the cushion pad 1 of the rear seat of the vehicle (FIGS. 1 to 3). If the cushion pad 1 is covered with the skin to form a seat cushion, the seat back with the known back pad covered with the skin becomes a rear seat having the auxiliary seat portion 3C in the vehicle width direction. FIG. 2 shows a cushion pad 1 in a vehicle-installed manner. The left-right direction of the paper surface indicates the vehicle width direction, the upper part of the paper surface indicates the upper part of the vehicle, and the same applies to the “vehicle width direction” and “upper side” in the present invention.
The cushion pad 1 includes a first foam molded body 2 and a second foam molded body 3.

The first foam molded body 2 is a raised foam molded body that occupies the lower layer of the cushion pad 1 (FIG. 3). The density (specifically, the apparent density) is smaller than that of the second foamed molded product 3, and the hardness is increased. For example, it is composed of a foam molded product obtained by a so-called bead foaming method. It is a block-shaped bead foam formed by pre-foam molding the raw material beads and then in-mold foam molding. The bead foam is preferably expanded polystyrene, expanded polypropylene, expanded polyethylene, or a molded product containing at least one of these. The beaded foam in which the bubbles are sealed inside is harder than the second foam molded body 3 by making most of the volume lightweight with gas, and has hardness and shape retention as a raising member for the cushion pad 1.

The first foam molded body 2 is provided with a raised portion 24 having a side wall surface 241 that is substantially vertical (substantially vertical) under the installation of a cushion pad on a vehicle on the back surface 2b side thereof (FIG. 2, Fig. 3). In the first foam molded body 2, a plurality of protruding bulges 25 are intermittently formed on the side wall surface 241 formed substantially vertically of the raised portion 24. Each bulge 25 may be a wart-shaped convex portion, but in the manufacture of the cushion pad, the bulge 25 is inserted into the concave hole 92 in order to compress the tip portion 251 of the bulge 25 and hold the raised portion 24 in the concave hole 92 described later. Vertical stripes extending in the direction are more preferable.

In this embodiment, a pair of raised portions 24 of substantially square pillars are formed apart from each other in the vehicle width direction, and here, they are arranged on both outer sides in the vehicle width direction. Then, a protruding bulge 25 is exposed and formed on the side wall surface 241 of both raised portions 24. In the vehicle installation of the cushion pad 1, the back surface 2b of the first foamed molded body 2 is arranged substantially horizontally, and the raised portion 24 having the side wall surface 241 as a substantially vertical surface with respect to the back surface 2b is downward (vertically). Protrude and stand up. When installed in a vehicle, the raised portion 24 is set to a height h protruding below the vehicle body floor surface 6.
The raised portion 24 has a rectangular shape when viewed from the back surface, and its long side is aligned with the vehicle front-rear direction. A bulge 25 is formed into vertical stripes on the side wall surface 241 of the raised portion 24, and a plurality of ridge bulges 25 project at a predetermined pitch in the circumferential direction orthogonal to the height direction of the raised portion 24 on the side wall surface 241. It is molded. In FIG. 3, a plurality of protruding bulges 25 are arranged in parallel leaving a flat portion of the side wall surface 241. However, the protruding bulges 25 may be continuously provided in a wavy shape without the flat surface.

The protruding bulge 25 here has a cross section orthogonal to the insertion direction of the raised portion 24 into the concave hole 92 as a triangle whose apex is on the protruding end side as shown in FIG. The cross-sectional shape of the bulge 25 is preferably tapered toward the tip of the bulge 25 in this way. In addition to a triangle, if the shape protrudes into a semicircle, ellipse, trapezoid, etc., the concave hole 92 and the bulge 25 will interfere with each other as they are in the manufacture of the cushion pad described later, and even if they are used at the hole opening of the concave hole 92, they will bulge. The tip portion 251 of 25 is a part of the first foam molded body 2 having a tapered shape and being compressible and deformable. Depending on the degree of interference, the tip portion 251 can be compressed and deformed relatively easily, and the raised portion 24 with the bulge 25 can be easily inserted and set in the concave hole 92.

Further, the first foam molded product 2 can be made into another aspect product having a two-divided structure as shown in FIG. The first foam molded product 2 in the figure shows only the split pad 2N corresponding to the right half side of FIG. 3, but is provided with a pair of split pads 2M on the left half side that are substantially plane-symmetrical, and is provided with a pair of split pads 2M in FIG. It becomes a cushion pad 1 like. A protruding bulge 25 is formed on all of the side wall surfaces 24 having four surfaces. Reference numeral 20 is a hole to prevent bottoming out when the occupant sits down.

FIG. 6A shows a partially enlarged view of FIG. 4 in which the raised portion 24 having the bulge 25 on the side wall surface 241 is raised from the back surface 2b of the first foamed molded product 2. FIG. 6 is a cross-sectional view of the circumference of the raised portion 24 on the back surface 2b side of the first foam molded body 2, and the vertical direction is reversed when the vehicle is installed.
A bulge 25 having the same cross-sectional shape is formed in a vertical streak ridge over the entire vertical direction of the ridge portion 24 that stands perpendicular to the back surface 2b of the first foam, and the bulge 25 is formed by a cushion pad manufacturing method described later. , Interferes with the concave hole 92 of the upper mold 9 to increase the holding force to the upper mold 9. Reference numeral 929 is a chamfer of the concave hole 92, which facilitates insertion of the raised portion 24 with the bulge 25 into the concave hole 92.

In order to prevent the raised portion 24 fitted into the concave hole 92 by interfering with the bulge 25, it is preferable that all the side wall surfaces 241 stand vertically with respect to the back surface 2b of the first foam. .. The bulges 25 may not be provided on all the side wall surfaces 241 of the raised portion 24, or may be provided on two opposing surfaces. The raised portion 24 set in the concave hole 92 may be able to maintain a state in which the side wall surface 241 does not come off during the manufacturing process of the cushion pad even if it is an upright surface close to a vertical surface slightly tilted. Further, while the side wall surface 241 is kept upright with respect to the back surface 2b, the cross section of the top surface 242 side of the raised portion 24 is smaller than that of the base end side so that the raised portion 24 can be easily fitted into the concave hole 92. It may be a raised portion 24 that serves as a vertical side wall surface 241 (b in FIG. 6). Even if the bulge 25 has a bulge 25 that strongly interferes with the concave hole 92, the bulge 25 with the bulge 25 is inserted into the concave hole 92 by setting the first foamed molded product 2 into the upper mold 9. Becomes easier. Even if the cross-sectional area of the bulge 25 is added to the area of the top surface 242 of the raised portion, it can be made smaller than the hole opening of the concave hole 92.

Further, the bulge 25 having an equal cross-sectional shape in the vertical direction in FIG. 6 (a) may be used, but the bulge 25 in which the cross-sectional shape is gradually reduced downward as shown in FIG. 6 (c) may be used. The bulge 25 increases the protrusion height f2 at the base end portion (back surface point) with respect to the protrusion height f1 at the top surface point. When the raised portion 24 with the bulge 25 is inserted into the concave hole 92, the bulge 25 and the concave hole inner wall 921 start to interfere with each other from the middle of the insertion, and the setting of the first foam molded body 2 in the upper mold 9 proceeds smoothly. Moreover, since the degree of interference gradually increases, the holding force on the upper mold 9 can be smoothly increased.
Further, the bulge 25 provided on the side wall surface 241 does not need to be provided over the entire area in the vertical direction, and the bulge 25 is provided from the middle of the side wall surface 241 slightly lowered from the top surface 242 to the back surface 2b side as shown in FIG. The starting point may start and the bulge 25 may extend to the streaks.

Further, the first foam molded product 2 may have a raised portion 24 as shown in FIG. 5 provided in the depressed region 23, for example. The first foamed molded product 2 is provided with a recessed area 23 that is one step lower inside the outer peripheral portion 22 of the back surface, and the depressed bottom 235 of the depressed area 23 is used as the back surface 2b of the first foamed molded product 2 as the back surface 2b. A raised portion 24 is formed by raising a part of the above. While the outer shape of the back surface is similar to that of FIG. 3, the outer peripheral portion 22 of the back surface is left over the entire circumference, and a depressed region 23 of a large depression such as a caldera is provided inside the outer peripheral portion 22 of the back surface. Then, the pair of raised portions 24 are raised in an island shape in the depressed areas 23 on both outer sides in the vehicle width direction. The top surface 242 of the raised portion 24 and the back surface of the back surface outer peripheral portion 22 are flush with each other, and the cushion pad 1 is installed on the floor surface 6 of the vehicle body to facilitate horizontal arrangement. In addition, in FIG. 5, since the cushion pad is manufactured by using the upper mold 9 in which the concave hole 92 for accommodating the pair of raised portions 24 is formed (details will be described later), the two raised portions 24 in FIG. 5 are present. The facing wall surfaces 241 on both sides have no bulge 25. The cross-sectional shape of the bulge 25 is semicircular (b in FIG. 8).
Reference numerals 2A, 2B, and 2C indicate a main lower layer, a side lower layer, and an auxiliary seat lower layer.

The second foam molded body 3 is a cushion body formed of a flexible polyurethane foam molded body, having a seat layer 31 having a contact surface portion 311 on the side where the seated occupant comes into contact with the seated occupant. The seat layer 31 is laminated on the first foam molded body 2 which is the lower layer for raising, and the second foam molded body 3 is foam molded. The seated occupant comes into contact with the contact surface portion 311 via a skin (not shown) that covers the cushion pad 1.

In FIGS. 1 and 2, in the second foam molded body 3, the seat layer 31 covers the core pad top surface 2a, and the side peripheral layer 32 covers the side surface 2d of the first foam molded body 2. The upper surface of the seat layer 31 related to the second foam molded body 3 is the design surface on the contact surface portion 311 side with which the seated occupant abuts, and the outer surface of the side peripheral layer 32 is the side design surface 3d of the second foam molded body 3. Become. The second foam molded body 3 covers and integrates with the first foam molded body 2 except for the back surface 2b of the first foam molded body 2, which also serves as the back surface 1b of the cushion pad, to complete the cushion pad 1.
Although not shown, the first foam molded body 2 is provided with a through hole for venting gas disclosed in Japanese Patent Application Laid-Open No. 2017-206077, which penetrates from the top surface 2a to the back surface 2b, and further, from the hole diameter of the through hole on the back surface 2b side. Also has a large depression. In the foam molding of the second foam molded body 3 described later, the second foam molded body 3 fills the through holes and dents with the second foam molded body 3, so that the second foam molded body 3 is integrally strengthened with the first foam. Reference numeral 3A indicates a main portion of a passenger seat, reference numeral 3B indicates a side portion, reference numeral 3D indicates a slope, reference numeral 3E indicates a mating portion with a backrest, and reference numeral 39 indicates a suspension groove.

(2) Manufacturing Method of Cushion Pad for Vehicle The cushion pad 1 is manufactured by the following manufacturing method, for example, when the first foam molded body 2 is shown in FIG. 5 (FIGS. 7 to 11). Using the foam molding mold 7, the second foam molding body 3 in which the contact surface portion 311 on the side where the occupant abuts is formed of the flexible polyurethane foam molding body is foam-molded, and the first foam molding body of the insert product is formed by the foam molding. Manufacture a vehicle cushion pad that is integrated with 2.

Prior to the production of the cushion pad, the first foam-molded body 2 and the foam-molded mold 7 are prepared. The first foam molded body 2 is the same as that described in (1) Cushion pad, and the description thereof will be omitted.
The foam molding mold 7 is a split mold as shown in FIG. 9, and the lower mold 8 and the upper mold 9 are connected so as to be openable and closable. When the mold is closed as shown in FIG. 10, the entire lower mold cavity surface 81, which is recessed like a bowl to form the design surface of the contact surface portion 311, and the entire back surface 2b of the first foam molded body 2 are substantially flat. A cushion pad cavity C is formed with the upper cavity surface 91. In the set of the first foam molded body 2 on the upper mold 9, a concave hole 92 as shown in the figure is formed on the upper mold cavity surface 91 at a position corresponding to the raised portion 24. Here, a large concave hole 92 as shown in FIG. 7 for accommodating a pair of raised portions 24 including the depressed bottom 235 is provided. The foam molding die 7 molds the cushion pad 1 of FIG. 5 in an inverted shape.

In the manufacturing method of this cushion pad, first, the foam molding mold 7 and the first foam molding body 2 are used, and the back surface 2b side of the first foam molding body 2 is turned up, and the two raised portions 24 are put together into one. The first foam molded body 2 is set in the upper mold 9 by fitting into the concave hole 92.
The concave hole 92 provided at the corresponding position of the raised portion 24 on the upper die cavity surface 91 can be accommodated only by the raised portion 24, but due to the presence of the bulge 25, the bulge 25 is recessed when the raised portion 24 is fitted. It collides with and interferes with the hole forming portion F. A bulge 25 can be used in the concave hole forming portion F on the periphery of the hole opening of the concave hole 92. However, since the bulge 25 is a part of the first foam molded body 2 and can be compression-deformed, the bulge 25 is fitted into the concave hole 92 while being compression-deformed, and the first mold 9 is fitted with the bulge 25. The foam molded body 2 can be set. When the raised portion 24 having the bulge 25 is pushed into the concave hole 92 by force, the bulge 25 that becomes an interference portion with the concave hole forming portion F is compressed by the concave hole inner wall 921 and elastically deformed. The raised portion 24 with the bulge 25 is inserted into the concave hole 92 in a state where the protruding tip portion 251 that interferes with the bulge 25 is crushed.

FIG. 8 shows the circumference of the concave hole forming portion F on the left side of FIG. 7 in which the raised portion 24 is fitted into the concave hole 92 and is in the set state. Reference numeral 252 indicates that the protruding portion 251 of the bulge 25 is crushed with the setting. Shows the compressed part. The elastic restoring force of the crushed compressed portion 252 presses the concave hole inner wall 921 in which the elastic restoring force stands up, and this pressing also occurs in the concave hole inner wall 921 of the right concave hole forming portion F in FIG. The set first foam molded body 2 is held. A bulge 25 is provided on the side wall surface 241 of the raised portion that stands up on the back surface 2b of the first foamed molded body 2, and as described in FIG. 9, the vertically standing concave hole inner wall 921 is formed by the raised portion 24 with the left and right bulges 25. Since the pressing is performed so as to stretch from the inside to both the horizontal and outward sides, the first foam molded body 2 is effectively held by the upper mold 9. It should be noted that the side wall surfaces of the raised portion 24 shown in FIG. 8 (b) located above and below the paper surface are not provided with the bulge 25. If a bulge 25 is also provided here and a concave hole forming portion F that interferes with the bulge 25 is formed, the raised portion 24 fitted into the concave hole 92 is also provided on the upper and lower inner walls of the concave hole 92 shown in FIG. The compressed portion formed by crushing the interfering tip portion 251 acts on the upper and lower inner walls 921 and is firmly held by the upper mold 9.

After that, the foaming raw material g for the second foamed molded product 3 is injected onto the lower mold cavity surface 81 using an injection nozzle NL or the like.
Subsequently, the upper mold 9 is operated to close the mold (FIG. 10). By closing the upper mold 9 and the lower mold 8, a cushion pad cavity C in which the first foam molded body 2 is insert-set is formed. In this embodiment, the mold is closed after the injection of the foamed raw material g, but the foamed raw material g can also be injected after the mold is closed.

After closing the mold, the process proceeds to foam molding of the second foam molded product 3. The second foam molded body 3 having the contact surface portion 311 on the design surface side and the inner surface 3b on the opposite side is brought into contact with the top surface 2a of the first foam molded body 2 to form the seat layer 31 is foam molded. To do. The mold closed state of FIG. 10 is maintained for a predetermined time, and the second foam molded product 3 of the flexible polyurethane foam molded product is foam molded. The contact surface portion 311 is formed by the lower mold cavity surface 81, and the second foam molded body 3 in which the inner surface 3b on the opposite side of the contact surface portion 311 is brought into contact with the top surface 2a of the first foam molded body 2 is foam molded. To do.
When the foam molding of the second foam molded body 3 is completed and the mold is removed, a desired cushion pad 1 that realizes weight reduction by incorporating the first foam molded body 2 is obtained (FIG. 5).

12 and 13 show another method of manufacturing a cushion pad in which the split pad 2N of FIG. 4 is used for the first foam molded body 2.
The first foam molded product 2 shown in FIG. 3 is divided into two parts, and the divided pads 2M and 2N are further provided with holes 20. A raised portion 24 is provided on each of the divided pads 2M and 2N, and a bulge 25 is formed on the side wall surface 241 of both raised portions 24. All four side wall surfaces 241 have vertical stripe bulges 25 as shown in FIG. The foam molding mold 7 is formed by closing the upper mold 9 and the lower mold 8 to form a cavity C substantially the same as that of the cushion pad 1 in FIG. A concave hole 92 is provided in each of the upper die cavity surfaces 91 corresponding to the two raised portions 24, and the concave hole 92 interferes with the bulge 25 while allowing the raised portion 24 to be accommodated. In the set of the split pads 2M and 2N on the upper die 9, the bulge 25 collides with the concave hole forming portion F on the periphery of the concave hole 92. However, the elastically deformable bulge 25 can crush and compress the interfering tip portion 251 to accommodate the bulge 25 with the bulge 25 in the concave hole 92.
In the right split pad 2N of FIG. 12, the elastic restoring force due to the initial tip portion 251 indicated by the chain line being crushed and compressed acts substantially horizontally outward from all the side wall surfaces 241 on the four surfaces of the raised portion 24. Since the concave hole inner wall 921 is pressed, the split pad 2N is securely set and held in the upper mold 9. Further, if the raised portion 24 with the bulge 25 is inserted into the concave hole 92, the raised portion 24 is formed into a substantially rectangular shape in a plan view, so that the dividing pad 2N is autonomously positioned and set in the upper mold 9. Similar to the right split pad 2N, after the left split pad 2M of FIG. 12 is set in the upper mold 9, the foamed raw material g for the second foam molded body 3 is injected onto the lower mold cavity surface 81. After that, the mold is closed and the second foam molded body 3 is foam molded to obtain a desired vehicle cushion pad 1 as shown in FIG.
Reference numeral S indicates an empty space, reference numeral 29 indicates a locking groove on the skin, and reference numerals 89 and 99 indicate a mold matching surface on the lower mold side and the upper mold side.

(3) Effect Like the vehicle cushion pad and its manufacturing method configured in this way, a part of the side wall surface on the back surface 2b side of the first foam molded body 2 is substantially vertical under the vehicle installation of the cushion pad. When the raised portion 24 is formed and the protruding bulge 25 is formed on the side wall surface 241 which is substantially vertical to the raised portion 24, the first foamed molded product 2 is used as an insert product and above. Can be easily set on the mold 9. The cushion pad 1 can be made by foam molding the second foam molded body 3.
When a concave hole 92 is formed in the upper die cavity surface 91 corresponding to the raised portion 24 and the raised portion 24 with the bulge 25 is inserted into the concave hole 92, the raised portion 24 fits in the concave hole 92, but the bulge 25 is a concave hole. It is set so as to collide and interfere with the circumference of the hole of 92. However, since the bulge 25 can be compressed and deformed as a part of the first foam molding, the tip portion 251 of the bulge 25 is crushed and compressed and deformed, and the bulge 25 with the bulge 25 is smoothly fitted into the concave hole 92. be able to. Then, a repulsive force acts on the compressed portion 252 in which the bulge 25 is crushed and deformed, and this repulsive force pushes the concave hole inner wall 921 outward from the compressed portion on the side wall surface 241 of the raised portion 24. The first foam molded body 2 is held in the mold 9.
In Patent Document 1, a protrusion is provided on the upper mold 9 to prevent the first foam molded body 2 from falling off, but the protrusion is made of a metal material of the mold and is hard, and the first foam molded body 2 causes molding shrinkage. Poor degree of freedom of deformation. If the degree of interference is as large as possible, it will be necessary to adjust the dimensions of the mold. On the other hand, the bulge 25 of the present invention is formed of a beaded foam such as expanded polypropylene even though it is harder than the second foamed molded product 3, and is a protruding bulge 25, so that it is too large. Even in this case, the bulging portion 24 with the bulge 25 can be easily inserted into the concave hole 92 by increasing the amount of crushing by that amount and deforming it. It becomes easy to set the first foam molded product 2 on the upper mold 9. Further, even if the raised portion 24 with the bulge 25 is forcibly inserted into the concave hole 92, the first foamed molded product 2 obtained by the bead foaming method or the like is compressed and deformed, so that the metal material has a hard protrusion. There is no defect of Patent Document 1 such as being scraped by a part.

When the bulge 25 formed into vertical stripes in the vertical direction is provided, the tip portion 251 of the bulge 25 is crushed and compressed and deformed over the entire area of the side wall surface 241 in the height direction, and the concave hole 92 is bulged with the bulge 25. Since the portion 24 can be fitted, the reaction force is increased by the amount of the area of the crushed compressed portion 252, and the holding force of the first foam molded body 2 on the upper mold 9 is improved. In the case of the first foam molded body 2 having the bulge 25 of the vertical stripes, undercut cannot be performed, so that the molding becomes easy. If a plurality of bulges 25 are provided in the circumferential direction of the side wall surface 241, the number of compressed portions 252 to be crushed increases to a plurality, so that the holding force of the first foam molded body 2 to the upper mold 9 is a plurality of bulges 25 in the case of one bulge 25. Double.
When the bulge 25 is formed so that its cross-sectional shape is reduced downward, the bulge 25 with the bulge 25 can be easily inserted into the concave hole 92. Then, the bulge 25 is made to interfere with the concave hole inner wall 921 from the middle of insertion, and the degree of interference is gradually increased, so that the holding force to the upper die 9 can be smoothly increased.

As shown in FIG. 2, a pair of raised portions 24 are formed apart from each other in the vehicle width direction, and both are arranged on both outer sides in the vehicle width direction, and when the cushion pad 1 is installed on the vehicle, both raised portions 24 are substantially vertical. When the bulge 25 is exposed and formed on the side wall surface 241 that serves as a guide, it becomes easy to set the frame 5 that guides and holds the cushion pad 1. Naturally, the frame 5 also has a dimensional error, but the bulge 25 absorbs this error (FIG. 2). Fine adjustment with the frame 5 side becomes possible by compressive deformation of the tip portion of the protruding bulge 25 protruding from the side wall surface 241 of the raised portion 24. The permissible range of the usable frame 5 is widened, which contributes to the improvement of the yield.
When the raised portion 24 is set to a height protruding below the vehicle body floor surface 6 in the installation on the vehicle, the raised portion 24 and the bulge 25 are accommodated in the vehicle body floor surface 6 facing the raised portion 24. If the recess 61 or the punched hole is provided, the cushion pad 1 can be easily attached and fixed to the vehicle body (FIG. 2). The cushion pad can be stopped against the rolling of the vehicle.

A recessed area 23 that is one step lower is provided inside the outer peripheral portion 22 of the back surface of the first foam molded body 2, and the depressed bottom 235 of the depressed area 23 is a part thereof as the back surface 2b of the first foam molded body 2. When the raised portion 24 is formed, there is almost no restriction on the place where the raised portion 24 is provided on the back surface 2b side of the first foam molded body 2, and the degree of freedom in design is increased.
As described above, the cushion pad for this vehicle and the method for manufacturing the cushion pad exhibit the various excellent effects described above.

The present invention is not limited to the one shown in the above embodiment, and various modifications can be made within the scope of the present invention according to the purpose and application. The shape, size, number, material, etc. of the cushion pad 1, the first foam molded body 2, the raised portion 24, the bulge 25, the second foam molded body 3, the foam molding mold 7, etc. can be appropriately selected according to the application. When the raised portions 24 are formed in pairs separated from each other in the vehicle width direction and both are arranged toward both outer sides, the bulges 25 need not be provided on all the side wall surfaces 241 of both raised portions 24, as shown in FIG. It suffices that at least the bulges 25 are exposed and formed on the opposite side wall surfaces 241 of both raised portions 24.

1 Cushion pad 2 1st foam molded body 24 raised part 241 side wall surface 25 bulge 3 2nd foam molded body 31 seat layer 311 contact surface part 81 lower cavity surface 91 upper cavity surface 92 concave hole 95 engaging part F concave hole Forming part g Foaming material

Claims (10)

In a vehicle cushion pad in which a second foam molded body in which a seat layer having a contact surface portion on the side where a seated occupant comes into contact is laminated on a first foam molded body to be a lower layer is foam molded.
The first foamed molded product has a smaller density and a higher hardness than the second foamed molded product, and has a side wall surface that is substantially vertical to a part of the back surface side of the first foam molded product when the cushion pad is installed on the vehicle. A cushion pad for a vehicle, characterized in that a raised portion is provided and a plurality of protruding bulges are formed on the side wall surface that is substantially vertical to the raised portion. The vehicle cushion pad according to claim 1, wherein a plurality of the bulges formed into vertical stripes in the vertical direction are provided in the circumferential direction of the side wall surface. The vehicle cushion pad according to claim 1 or 2, wherein the bulge is formed by reducing its cross-sectional shape downward. Claim 1 in which a pair of raised portions are formed apart from each other in the vehicle width direction, both are arranged on both outer sides in the vehicle width direction, and the bulges are exposed and formed on opposite side wall surfaces in both raised portions. The vehicle cushion pad according to any one of 3 to 3. The vehicle cushion pad according to any one of claims 1 to 4, wherein the raised portion is set to a height protruding downward from the floor surface of the vehicle body when installed in a vehicle. A lower recessed area is provided inside the outer peripheral portion of the back surface of the first foamed molded product, and a part of the depressed bottom of the depressed region is used as the back surface of the first foamed molded product to raise the raised portion. The vehicle cushion pad according to any one of claims 1 to 5, wherein the cushion pad for a vehicle is formed. In a method for manufacturing a cushion pad for a vehicle, which foam-molds a second foam-molded body in which a seat layer having a contact surface portion on a side where a seated occupant comes into contact is laminated on a first foam-molded body to be a lower layer.
The first foamed molded product has a smaller density and a higher hardness than the second foamed molded product, and has a side wall surface that is substantially vertical to a part of the back surface side when the cushion pad is installed on the vehicle. A plurality of ridge bulges are formed on the side wall surface which is substantially vertical to the raised portion, and a concave hole corresponding to the raised portion is formed on the upper cavity surface.
The back surface side of the first foamed molded product is turned upward, and the raised portion is fitted into the concave hole while compressing and deforming the bulge, and the first foamed molded product is set in the upper mold.
Next, the foamed raw material for the second foamed molded product is injected onto the lower mold cavity surface and the mold is closed.
After that, a method for manufacturing a cushion pad for a vehicle, which comprises foam-molding a second foam-molded body. The method for manufacturing a cushion pad for a vehicle according to claim 7, wherein a plurality of the bulges formed into vertical stripes in the vertical direction are formed on the side wall surface. The method for manufacturing a cushion pad for a vehicle according to claim 7 or 8, wherein the cross-sectional shape of the bulge is reduced downward. Any of claims 7 to 9, wherein a pair of the raised portions are formed apart from each other in the vehicle width direction, both are arranged on both outer sides in the vehicle width direction, and the bulges are formed on the opposite side wall surfaces of both raised portions. The method for manufacturing a cushion pad for a vehicle according to item 1.

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