JP2021037012A - Vehicle seat component and manufacturing method thereof - Google Patents

Abstract

To provide a vehicle seat component including an inexpensively-formed air passage for exerting an air-conditioning function in the vehicle seat component in which an upholstery material and a seat pad are formed of integral foam molding, and a manufacturing method thereof.SOLUTION: A seat component 10 is so formed that a cushion cover 11 as an upholstery material is integrated with a cushion pad 12 as a cushion material in a state in which the cushion cover is planarly joined by integral foam molding of the cushion pad 12. The cushion cover 11 includes a surface layer 11a disposed at a seat surface side and having high air permeability, and a rear surface layer 11b disposed at the cushion pad 12 side, with a gap part 11s communicated with the surface layer 11a in an in-plane direction, and having air permeability lower than that of the connected surface layer 11a. A part of the gap part 11s is connected to a blower 5.SELECTED DRAWING: Figure 1

Description

The present invention relates to a vehicle seat component and a method for manufacturing the same. More specifically, the present invention relates to a vehicle seat component in which a skin material and a seat pad are integrally formed by integral foam molding, and a method for manufacturing the same.

Conventionally, there is known a vehicle seat component in which a skin material and a seat pad are integrally formed by integral foam molding. Some of the vehicle seat components have an air-conditioning function that blows air supplied from the blower toward the seated person's body through a flow path portion provided in the vehicle seat component. In the vehicle seat component described in Patent Document 1, after the skin material and the seat pad are integrally formed by integral foam molding, a through hole serving as an air flow path is formed between the skin material and the seat pad. Is forming.

Japanese Unexamined Patent Publication No. 2013-86679

When the skin material and the seat pad are integrally foam-molded, it is necessary to prevent the seat pad molding material from invading the skin material and solidifying and hindering the flexibility of the skin material. In the member, slab urethane having low air permeability is laminated on the surface of the skin material on the seat pad side. Then, after the integral foam molding, a through hole was partially provided in the slab urethane having low air permeability by punching with a punch member in order to provide an air flow path portion between the skin material and the seat pad. As a result, there is a problem that the processing process becomes complicated and the manufacturing cost tends to be high.

In view of such a problem, an object of the present invention is for a vehicle seat component in which a skin material and a seat pad are integrally formed by foam molding, in which an air flow path for performing an air conditioning function is inexpensively formed. The present invention provides a sheet component and a method for manufacturing the same.

The first invention of the present invention is a state in which a seat cover, which is a skin material, is joined to a seat pad, which is a seat component for a vehicle, as a cushion material in a planar shape by integral foam molding of the seat pad. The seat cover is integrated with the seat cover in a state where the seat cover is arranged on the seating surface side and a gap portion communicating in the in-plane direction is provided between the surface layer having high air permeability and the surface layer. It has a back surface layer having a lower air permeability than the front surface layer arranged and connected to the side, and the gap portion is characterized in that a part thereof is connected to a blower.

According to the first invention, the seat cover is formed to have a gap portion which is communicated in the in-plane direction by the front surface layer and the back surface layer. Then, when air is supplied into the gap or air is sucked from the gap by a blower connected to a part of the gap, air is blown around the seated person's body through a surface layer having high air permeability. The air around the seated person's body is sucked in and the air conditioning function is fulfilled. As a result, it is possible to inexpensively obtain a seat component for a vehicle in which an air flow passage is formed only by integrally foam-molding the seat pad with respect to the seat cover provided with the gap portion.

A second aspect of the present invention is the support for preventing the gap portion from being deformed by the pressure of foaming during integral foam molding of the seat pad with respect to the seat cover in the gap portion in the first invention. It is characterized in that the members are arranged.

According to the second invention, since it is possible to suppress the deformation of the gap portion during the integral foam molding of the seat pad with respect to the seat cover, the gap portion can be effectively functioned as an air flow path.

A third aspect of the present invention is characterized in that, in the above two inventions, the support member is a three-dimensional three-dimensional knitted object formed corresponding to the shape of the gap portion.

According to the third invention, the support member can be rationally formed and the air flow can be less likely to be obstructed.

According to the fourth aspect of the present invention, in any one of the first invention to the third invention, the portion of the back surface layer corresponding to the gap is foamed during integral foam molding of the seat pad with respect to the seat cover. It is characterized in that a rib is formed to prevent the gap portion from being deformed by pressure.

According to the fourth invention, since ribs are formed in the portion of the back surface layer corresponding to the gap portion, it is possible to prevent the gap portion from being deformed by the pressure of foaming during the integral foam molding of the seat pad with respect to the seat cover. ..

A fifth aspect of the present invention is characterized in that, in the fourth aspect of the present invention, the ribs are provided in a direction substantially orthogonal to the flow direction of air flowing in the gap portion.

According to the fifth invention, it is possible to make the shape of the void portion less likely to be deformed more effectively.

The sixth invention of the present invention is characterized in that, in any one of the first invention to the fifth invention, the back surface layer is formed of a non-woven fabric.

According to the sixth invention, the back surface layer can be formed at low cost.

A seventh aspect of the present invention is the method for manufacturing a vehicle seat component according to the first aspect of the present invention, with respect to a lower mold having an inner surface corresponding to the shape of the seat pad on the seating surface side and the lower mold. The seat cover is prepared with an upper mold that is closed to form a cavity in the shape of the seat pad, and the back surface layer formed in advance with respect to the front surface layer in the lower mold is connected to form the gap portion. A step of setting the surface layer side so as to abut the inner surface, a step of injecting a urethane foam resin material into the cavity, closing the upper mold, and foaming and curing the urethane foam resin material, and the urethane foam resin. It is characterized by including a step of opening the upper mold and removing the vehicle seat constituent member after the material is foamed and hardened.

According to the seventh invention, a seat cover in which a gap portion is formed in advance is set in the cavity of the lower mold, and a urethane foam resin material is injected and integrally foam molded, so that the seat configuration for a vehicle according to the first invention is efficiently performed. Members can be manufactured.

It is a perspective view of the automobile seat to which the seat constituent member which is one Embodiment of this invention is applied. It is an exploded perspective view of the cushion cover of the seat constituent member in the said embodiment. FIG. 3 is a cross-sectional view taken along the line III-III of FIG. It is sectional drawing which shows typically the foam molding mold. It is sectional drawing which shows typically the state which set the cushion cover in the foam molding mold. It is sectional drawing which shows typically the state in which the seat constituent member for a vehicle in the said embodiment is integrally foam-molded by the upper die and the lower die. It is a perspective view of the back surface layer of the cushion cover in another embodiment. FIG. 7 is a cross-sectional view taken along the line of arrows VIII-VIII of FIG.

1 to 3 show a seat component 10 according to an embodiment of the present invention. The seat component 10 is a member applied to the seat cushion 2 of the automobile seat 1. In each figure, the arrows indicate the directions of the automobile and the automobile seat 1 when the automobile seat 1 is attached to the automobile. In the following description, the description regarding the direction shall be made with reference to this direction. Here, the seat constituent member 10 corresponds to the "vehicle seat constituent member" in the claims.

As shown in FIG. 1, the automobile seat 1 includes a seat cushion 2 as a seating portion, a seat back 3 as a backrest, and a headrest 4 for supporting the head. The seat cushion 2 includes a cushion frame (not shown) forming a skeleton, a seat constituent member 10 mounted on the cushion frame, and a blower 5 for supplying air to the seat constituent member 10. .. The blower device 5 is attached to the cushion frame under the seat component 10 by, for example, a sirocco fan or the like.

As shown in FIGS. 1 to 3, the seat constituent member 10 is formed in a state in which the cushion cover 11 which is a skin material and the cushion pad 12 which is a cushion material are joined in a planar shape by integral foam molding. The cushion cover 11 has a surface layer 11a arranged on the seating surface side and a back surface layer 11b integrally attached to the surface of the surface layer 11a opposite to the seating surface. The surface layer 11a is formed by cutting a planar member in which a cover pad made of urethane foam slab is integrally laminated on the skin of a fabric or the like into a plurality of parts along the outer shape of the cushion pad 12 and sewing the surface layer 11a. It was done. The surface layer 11a is located on the left and right sides of the main top plate portion 11a1 that abuts on the lower surface portion of the buttock portion and the thigh portion of the seated person, and the side surfaces of the buttock portion and the thigh portion of the seated person. It has a bank portion 11a2 that abuts on the portion. The back surface layer 11b is made by heat-press molding a non-woven fabric having a lower air permeability than the front surface layer 11a, and has a surface shape along the surface opposite to the seating surface of the main top plate portion 11a1 of the front surface layer 11a. Further, a recess 11b1 that opens to the side of the main top plate portion 11a1 is provided in the central portion. When the back surface layer 11b is connected to the front surface layer 11a, the portion surrounded by the surface of the front surface layer 11a opposite to the seating surface and the inner surface of the recess 11b1 of the back surface layer 11b is the gap portion 11s. A blower pipe 5a for supplying air from the blower device 5 into the gap portion 11s is connected to the recess 11b1. In the gap portion 11s, a three-dimensional three-dimensional knitting object 11c formed in the shape of the gap portion 11s is arranged. The three-dimensional three-dimensional knitting object 11c is a planar member in which natural fibers and synthetic fibers are three-dimensionally knitted, and is a structure having a space between the meshes of fibers and having high air permeability. The back surface layer 11b is integrally attached to the surface of the front surface layer 11a opposite to the seating surface in a state where the three-dimensional three-dimensional knitting object 11c is arranged in the gap portion 11s. As a specific mounting method, the terminal portion of the back surface layer 11b is connected by sewing S, and the overlapping portion with the front surface layer 11a is connected by adhesion. This adhesion may be carried out by applying an adhesive, or by using a urethane resin impregnated in the back surface layer 11b at the time of integral foam molding of the cushion pad 12, which will be described later. A cushion pad 12 made of urethane foam resin is attached to the surface of the cushion cover 11 opposite to the seating surface by integral foam molding. Here, the cushion cover 11, the cushion pad 12, and the three-dimensional three-dimensional knitting object 11c correspond to the "seat cover", "seat pad", and "support member" in the claims, respectively.

A method of manufacturing the seat constituent member 10 will be described with reference to FIGS. 4 to 6. As shown in FIG. 4, a lower mold 21 having a surface 21a corresponding to the shape of the cushion pad 12 on the seating surface side and an upper mold 22 having a back surface 22a corresponding to the shape of the cushion pad 12 on the side opposite to the seating surface. , Prepare. When the upper mold 22 is closed with respect to the lower mold 21, a cavity 23 in the shape of a cushion pad 12 is formed between the front surface 21a and the back surface 22a. As shown in FIG. 5, the cushion cover 11 is arranged on the surface 21a of the lower mold 21 with the upper mold 22 open so that the surface layer 11a abuts on the surface 21a. At this time, the end portion 11b2 of the cushion cover 11 is folded back and placed on the parting surface 21b of the lower mold 21. In this state, the urethane foam raw material is injected onto the back surface layer 11b of the cushion cover 11. Then, as shown in FIG. 6, the upper mold 22 is closed with respect to the lower mold 21 to foam and cure the urethane foaming material. At this time, the upper die 22 is engaged with the lower die 21, and the end portion 11b2 of the cushion cover 11 is sandwiched between the parting surface 21b of the lower die 21 and the parting surface 22b of the upper die 22. It is in a state of being. As the foaming gas generated in the process of foaming and curing the urethane foaming material is discharged to the outside of the cavity 23 through the cover pad of the cushion cover 11, the urethane foam is formed from the cavity 23 side surface of the cover pad of the back surface layer 11b and the front surface layer 11a. A part of the foaming material invades and solidifies. As a result, the cushion cover 11 and the cushion pad 12 are joined and integrated in a planar shape. Then, a part of the urethane foaming raw material that has penetrated into the back surface layer 11b reaches the cover pad of the front surface layer 11a that overlaps the back surface layer 11b and solidifies, so that the back surface layer 11b and the front surface layer 11a are joined and integrated in a plane shape. To. This makes it possible to omit the step of adhering the back surface layer 11b to the front surface layer 11a in advance. The lower mold 21 and / or the upper mold 22 may be heated as necessary while the urethane foaming raw material is foamed and cured. In the process of foaming and curing the urethane foaming raw material, the recess 11b1 of the back surface layer 11b receives foaming pressure in the direction of being crushed, but since the three-dimensional three-dimensional knitting object 11c is arranged in the gap 11s, crushing is suppressed. Will be done. Here, the surface 21a corresponds to the "inner surface" of the claims.

The present embodiment configured as described above has the following effects. The cushion cover 11 is formed to have a gap portion 11s in which the front surface layer 11a and the back surface layer 11b communicate with each other in the in-plane direction. Then, when air is supplied into the gap 11s by the blower pipe 5a of the blower device 5 connected to a part of the recess 11b1, air is blown around the seated person's body through the surface layer 11a having high air permeability to air-condition the air. The function is fulfilled. As a result, the seat constituent member 10 in which the air flow path is formed can be obtained at low cost only by integrally foam-molding the cushion pad 12 with respect to the cushion cover 11 provided with the gap portion 11s.

Further, in the gap portion 11s of the cushion cover 11, a three-dimensional three-dimensional knitting object 11c for preventing the gap portion 11s from being deformed by the pressure of foaming during integral foam molding of the cushion pad 12 is arranged. As a result, it is possible to prevent the gap portion 11s from being deformed during the integral foam molding of the cushion pad 12 with respect to the cushion cover 11, so that the gap portion 11s can effectively function as an air flow path. Further, since the back surface layer 11b is made of a non-woven fabric, the back surface layer 11b can be formed at low cost.

7 and 8 show the back surface layer 11Ab applied to the cushion cover 11A of the seat constituent member 10A according to another embodiment of the present invention. The difference from the back surface layer 11b is that a plurality of ribs 11Ab11 are partially provided in the recess 11Ab1. The ribs 11Ab 11 are arranged in a direction substantially orthogonal to the flow direction F of the air flowing through the gap portion 11s, and are formed in the hot press molding of the back surface layer 11Ab. Regarding other configurations, there is no difference between the configuration of the seat constituent member 10A and the seat constituent member 10. Due to the presence of the plurality of ribs 11Ab11, the recess 11Ab1 can suppress the deformation of the gap 11s when the cushion pad 12 is integrally foamed with respect to the cushion cover 11 as compared with the recess 11b1. In the present embodiment as well, the three-dimensional three-dimensional knitting object 11c may be arranged in the gap portion 11s as in the above-mentioned one embodiment. Here, the seat constituent member 10A and the cushion cover 11A correspond to the "vehicle seat constituent member" and the "seat cover" in the claims, respectively.

Although the specific embodiments have been described above, the present invention is not limited to their appearance and configuration, and various changes, additions, and deletions can be made without changing the gist of the present invention. For example, the following can be mentioned.

1. 1. In the above embodiment, the present invention is applied to the seat cushion 2 of the automobile seat 1, but it can also be applied to the seat back 3. Furthermore, it can be applied to seats of railway vehicles, airplanes, ships and the like.

2. In the above embodiment, the three-dimensional three-dimensional knitting object 11c is arranged in the gap portion 11s, but the present invention is not limited to this, and a non-woven fabric formed into a shape along the inner surface of the recess 11b1 can be arranged as a support member.

1 Automotive seat 2 Seat cushion 5 Blower 10 Seat component (Vehicle seat component)
10A seat component (vehicle seat component)
11 Cushion cover (seat cover)
11a Front surface layer 11b Back surface layer 11b1 Recess 11c Three-dimensional three-dimensional knitting object (support member)
11s gap 11A Cushion cover (seat cover)
11Ab Back surface layer 11Ab1 Recess 11Ab11 Rib 12 Cushion pad (seat pad)
21 Lower mold 21a Surface (inner surface)
22b Parting surface 22 Upper mold 22a Back surface 23 Cavity

Claims (7)

It is a vehicle seat component and
The seat cover, which is a skin material, is integrated with the seat pad, which is a cushion material, in a state where the seat cover is joined in a planar shape by integral foam molding of the seat pad.
The seat cover is arranged and connected to the seat pad side in a state where a surface layer having high air permeability is arranged on the seating surface side and a gap portion communicating in the in-plane direction is provided between the surface layer. It has a back surface layer with lower air permeability than the front surface layer.
The gap is a vehicle seat component whose part is connected to a blower. In claim 1, a vehicle seat in which a support member for preventing the gap portion from being deformed by the pressure of foaming during integral foam molding of the seat pad with respect to the seat cover is arranged in the gap portion. Components. In claim 2, the support member is a vehicle seat constituent member which is a three-dimensional three-dimensional knitted object formed corresponding to the shape of the gap portion. In any one of claims 1 to 3, the gap portion of the back surface layer corresponding to the gap portion is deformed by the pressure of foaming during integral foam molding of the seat pad with respect to the seat cover. A vehicle seat component in which ribs are formed to prevent In claim 4, the rib is a vehicle seat component member provided in a direction substantially orthogonal to the flow direction of air flowing in the gap portion. In any one of claims 1 to 5, the back surface layer is a vehicle seat constituent member formed of a non-woven fabric. The method for manufacturing a vehicle seat component according to claim 1.
A lower mold having an inner surface corresponding to the shape of the seat pad on the seating surface side and an upper mold that is closed with respect to the lower mold to form a cavity in the shape of the seat pad are prepared.
A step of setting the seat cover in which the gap portion is formed by connecting the back surface layer molded in advance to the surface layer in the lower mold so that the surface layer side abuts on the inner surface.
A step of injecting a urethane foam resin material into the cavity, closing the upper mold, and foaming and curing the urethane foam resin material.
A method for manufacturing a vehicle seat constituent member, which comprises a step of opening the upper mold and removing the vehicle seat constituent member after the urethane foam resin material is foamed and cured.

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