JP2021059276A - Manufacturing method of constitution member of vehicle seat - Google Patents

Abstract

To provide a manufacturing method which manufactures a constitution member of a vehicle seat having an air-conditioning function while suppressing the increase in the cost.SOLUTION: There is provided a manufacturing method of a back constitution member 3C in which a back pad 3p and a back cover 3s are integrated at the foam molding of the back pad 3p. The back cover 3s comprises: a surface layer part 10 which has the air permeability; a functional layer part 20 which is laminated on the side opposite to the seating surface of the surface layer part 10 and has the air permeability; a spacer part 30 which is partially laminated on the side opposite to the seating surface of the functional layer part 20 and has the air permeability; and an intrusion prevention layer part 40 which is laminated on the side opposite to the spacer part 30 and the seating surface of the functional layer part 20. The manufacturing method comprises: a first step of integrating the back cover 3s at the molding of the back pad 3p; and a second step of forming a channel part 5 by penetrating the back pad 3p and the intrusion prevention layer part 40 from the side opposite to the seating surface of the back pad 3p. In the second step, the channel part 5 is formed to the middle in the thickness direction of the spacer part 30.SELECTED DRAWING: Figure 7

Description

The present invention relates to a method for manufacturing a constituent member of a vehicle seat.

Conventionally, in an automobile seat, a seat cushion or a seat back is formed by placing a seat component manufactured by integrally foam molding a pad body which is a cushion material with respect to a skin material on a frame as a skeleton. There is something that has been done. In order to provide an air-conditioning function around the body of a seated occupant in such an automobile seat, it is necessary to provide a flow path portion through which air can pass in the seat constituent member. The constituent members of the automobile seat described in Patent Document 1 are formed by integrally foam molding a pad body which is a cushioning material with respect to the skin material, and then directed from the back surface (the surface opposite to the seating surface) of the pad material toward the skin material. By invading the punch member, a hole portion serving as an air flow passage is formed.

Japanese Unexamined Patent Publication No. 2013-216196

In the above-mentioned automobile seat, the skin material has a first portion in which the skin portion, the functional portion, and the spacer portion are laminated in a layered manner, and has low air permeability to prevent the pad body forming material from invading during foam molding of the pad body. It has a two-layer structure in which the second part is laminated in layers. Then, when the punch member is invaded after foam molding of the pad body to provide a hole in the pad body and the second portion, the punch member may reach the functional portion and damage the functional portion. Therefore, the functional portion and the second portion may be damaged. A spacer portion is provided between the portion. As a result, when the hole portion is provided, the risk of damaging the functional portion can be reduced, but the spacer portion needs to be provided over almost the entire surface of the skin material, so that the cost of the skin material tends to increase.

In view of such a demand, an object of the present invention is to provide a manufacturing method for manufacturing a component member of a vehicle seat having an air-conditioning function while suppressing an increase in cost.

The first invention of the present invention is a method for manufacturing a constituent member of a vehicle seat, in which a pad body as a cushioning material and a skin material covering the pad body are integrated at the time of foam molding of the pad body. The skin material is arranged on the seating surface side and has a breathable surface layer portion, the functional layer portion which is laminated on the side opposite to the seating surface of the surface layer portion and has breathability, and the seating of the functional layer portion. The molding material of the pad body at the time of foam molding of the spacer portion having breathability partially laminated on the side opposite to the surface and the pad body laminated on the side opposite to the seating surface of the spacer portion and the functional layer portion. The first step of integrating the skin material and the pad body at the time of molding the pad body, and the pad body from the side opposite to the seating surface of the pad body. And a second step of forming a flow path portion through which the air can pass through the intrusion prevention layer portion, and in the second step, the flow path portion is formed halfway in the thickness direction of the spacer portion. It is characterized by being done.

According to the first invention, the spacer portion is partially laminated on the side opposite to the seating surface of the functional layer portion, and the flow path portion is formed halfway in the thickness direction of the spacer portion in the second step. As a result, the air supplied through the flow path portion can be discharged from the seating surface of the skin material, and the spacer portion can be made smaller than the case where the spacer portion is arranged over the entire surface of the functional layer portion, and the material cost can be reduced. It becomes.

In the second invention of the present invention, in the first invention, the spacer portion is provided corresponding to the flow path portion, and is formed in a size that covers at least the entire cross section of the flow path portion. It is characterized by.

According to the second invention, the size of the spacer portion can be made smaller, so that a larger material cost can be reduced.

The third invention of the present invention is characterized in that, in the first invention or the second invention, the formation of the flow path portion in the second step is performed by a drill.

According to the third invention, the flow path portion can be formed by a simple method.

According to the fourth aspect of the present invention, in any of the first invention to the third invention, the portion of the pad body forming the flow path portion is located on the side opposite to the seating surface of the pad body in the first step. It is characterized in that a concave thin-walled portion is formed toward the skin material.

According to the fourth invention, it becomes easy to provide the flow path portion in the pad body in the second step.

It is a perspective view which looked at the car seat diagonally from the front. It is sectional drawing of the constituent member of the automobile seat. It is sectional drawing which shows by disassembling the skin material. It is a figure explaining the process of integrating a skin material and a pad body. The state where the skin material is attached to the molding die is shown. It is a figure explaining the process of integrating a skin material and a pad body. It shows a state in which the molding material of the pad body is injected and the molding mold is closed. It is a figure explaining the process of integrating a skin material and a pad body. It shows a state in which the pad body is hardened in the molding die and the skin material and the pad body are integrated. It is sectional drawing of the constituent member when forming a flow path portion. It is sectional drawing which shows by disassembling the skin material which concerns on the modification.

1 to 7 show an embodiment of the present invention. This embodiment is an example in which the present invention is applied to an automobile seat 1. In each figure, the arrows indicate the directions of the automobile seat 1 and the automobile 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. The automobile seat 1 of the present embodiment has a seat cushion 2 as a seating portion and a seat back 3 as a backrest. Here, the automobile seat 1 corresponds to the "vehicle seat" in the claims.

As shown in FIG. 1, the seat cushion 2 has a cushion frame 2f forming a skeleton and a cushion component 2C mounted on the cushion frame 2f. The cushion component 2C has a cushion pad 2p which is a cushion material and a cushion cover 2s which is a skin material. A blower 4 is arranged below the seat cushion 2, and a plurality of air blown from the blower 4 is supplied to the seated occupant through a flow path portion 5 having a circular cross section provided on the cushion component 2C. It can be blown. The seat back 3 has a back frame 3f forming a skeleton and a back component 3C mounted on the back frame 3f. The back component 3C has a back pad 3p which is a cushion material and a back cover 3s which is a skin material. A blower 4 is provided at the rear of the seat back 3, and air blown from the blower 4 can be blown to the seated occupant through a plurality of flow paths 5 provided in the back component 3C. Here, the cushion pad 2p and the back pad 3p each correspond to the "pad body" in the claims. The cushion cover 2s and the back cover 3s correspond to the "skin material" in the claims, respectively. The cushion component 2C and the back component 3C correspond to the "components" in the claims, respectively.

The seat cushion 2 and the seat back 3 have substantially the same structure, and the cushion frame 2f and the back frame 3f, and the cushion constituent member 2C and the back constituent member 3C correspond to each other. Therefore, the seat back 3 will be described as a representative.

As shown in FIG. 2, the back cover 3s has a surface layer portion 10, a functional layer portion 20, a spacer portion 30, and an intrusion prevention layer portion 40. The surface layer portion 10 is a portion arranged on the seating surface side, and has a surface material 11 on the seating surface side and a ventilation material 12 arranged on the rear side (opposite side of the seating surface) of the surface material 11. The surface material 11 is made of a leather material provided with a plurality of small-diameter through holes 11a, and the ventilation material 12 is made of slab urethane having a ^{high air permeability (about 200 to 400 cc / cm 2 · sec).} The surface material 11 and the ventilation material 12 maintain high air permeability in a state of being integrated by adhesion. The functional layer portion 20 is a portion arranged on the rear side (opposite side to the seating surface) of the surface layer portion 10, and is a planar body having a conductive wire that can be energized attached to the cloth and has a heater function or a sensor function. High air permeability. The functional layer portion 20 is attached to the surface layer portion 10 by adhesion that does not impede air permeability. ^{The spacer portion 30 is made of slab urethane having a high air permeability (about 200 to 400 cc / cm 2} · sec) equivalent to that of the ventilation material 12, and is formed on the rear side (opposite the seating surface) of the functional layer portion 20. It is partially arranged. Specifically, the spacer portion 30 is formed in a disk shape having a diameter slightly larger than the diameter of the flow path portion 5, and is attached to the functional layer portion 20 by adhesion that does not impede air permeability. As will be described later, when the flow path portion 5 is formed in the spacer portion 30 by the drill 60, the flow path portion 5 fits within the thickness of the spacer portion 30 and does not penetrate. The intrusion prevention layer portion 40 is a portion arranged on the rear side (opposite side to the seating surface) of the functional layer portion 20 and the spacer portion 30, and is ^{a slab urethane having a low air permeability (about 1 to 10 cc / cm 2} · sec). Is formed of. The intrusion prevention layer portion 40 has a function of preventing the molding material M (see FIG. 5) of the back pad 3p from invading the functional layer portion 20 during foam molding of the back pad 3p. The intrusion prevention layer portion 40 is formed with a recess 41 in which the spacer portion 30 is fitted and supported in a portion where the spacer portion 30 is arranged. When the spacer portion 30 is fitted into the recess 41, the surface of the spacer portion 30 on the seating surface side and the surface of the intrusion prevention layer portion 40 other than the recess 41 on the seating surface side are the same surface. The recess 41 of the intrusion prevention layer portion 40 is formed by hot press molding the intrusion prevention layer portion 40.

As shown in FIG. 2, the back pad 3p is a member forming the outer shape of the seat back 3, and has a thin-walled portion 3pa and a backing material 3pb. The back pad 3p is made of polyurethane foam having a density of 10 to 60 kg / m ^3. The thin-walled portion 3pa is formed corresponding to the portion where the spacer portion 30 is arranged. The shape of the thin portion 3pa may be circular when viewed from the side opposite to the seating surface, or may be rectangular extending in the vertical direction or the horizontal direction. The thickness of the thin portion 3pa is set to about 1/4 of the general portion. As will be described later, a flow path portion 5 is formed in the thin-walled portion 3pa by a drill 60 to allow air sent from the blower device 4 to pass through. The thin-walled portion 3pa is not essential and may be omitted as long as it does not interfere with the formation of the flow path portion 5 by the drill 60. The backing material 3pb is a planar member capable of reinforcing a portion of the back pad 3p that comes into contact with the back frame 3f on the rear side (opposite the seating surface), and a non-woven fabric is preferably used. As will be described later, the backing material 3pb is arranged in a portion other than the thin-walled portion 3pa and integrally molded when the back pad 3p is foam-molded.

A method of manufacturing the back component 3C will be described with reference to FIGS. 4 to 7. The back component 3C is manufactured by molding the back pad 3p in the molding die 50 and at the same time integrating it with the back cover 3s. The molding die 50 has a lower die 51 and an upper die 52 that forms a cavity 53 having a shape that conforms to the shape of the back pad 3p between the lower die 51 when it is closed to the lower die 51. The cavity surface 51a of the lower mold 51 is formed in a shape corresponding to the shape of the surface on the rear side (opposite the seating surface) of the back pad 3p, and the cavity surface 52a of the upper mold 52 is the front side (seat) of the back pad 3p. It is formed in a shape corresponding to the shape of the surface (on the surface side). That is, although not shown, a protruding portion for forming a thin-walled portion 3pa is formed at a predetermined position on the cavity surface 51a of the lower mold 51.

The first step will be described with reference to FIGS. 4 to 6. As shown in FIG. 4, the back cover 3s is set so that the surface material 11 comes into contact with the cavity surface 52a of the upper mold 52, and the backing material 3pb is set on the cavity surface 51a of the lower mold 51. Next, as shown in FIG. 5, the molding material M is injected onto the cavity surface 51a of the lower mold 51 to close the upper mold 52 with respect to the lower mold 51. The molding material M is filled in the cavity 53 while foaming and expanding, and is cured in that state as shown in FIG. 6, whereby the back pad 3p is molded and at the same time integrated with the back cover 3s. At this time, the intrusion prevention layer portion 40 of the back cover 3s prevents the molding material M from invading the side of the functional layer portion 20, so that the molding material M does not invade the functional layer portion 20 and the spacer portion 30. High air permeability is maintained. Further, the backing material 3pb is cured in a state where the molding material M has penetrated, and the backing material 3pb is integrated with the back pad 3p.

The second step will be described with reference to FIG. A plurality of flow path portions 5 are formed in the back component 3C. The back component 3C is set on the base (not shown) with the back pad 3p side down. A columnar drill 60 having a cutting edge at the tip is raised from below toward the base to form a flow path portion 5 which is a columnar hole in the thin-walled portion 3pa of the back pad 3p, the intrusion prevention layer portion 40, and the spacer portion 30. To do. At this time, the thin-walled portion 3pa and the intrusion prevention layer portion 40 are formed as holes through which the flow path portion 5 penetrates, and the spacer portion 30 is formed as a bottomed hole halfway in the thickness direction thereof. Even if the size for raising the drill 60 varies due to the presence of the spacer portion 30, it is possible to suppress the possibility that the drill 60 reaches the functional layer portion 20 and damages the functional layer portion 20. Further, since the spacer portion 30 is made of slab urethane having a high air permeability equivalent to that of the ventilation material 12, the air flow from the flow path portion 5 to the surface layer portion 10 is not obstructed.

The seat back 3 is assembled as follows. As shown in FIG. 1, the back component 3C is placed with the blower 4 attached to the back frame 3f, and the flow path portion 5 and the blower 4 are connected by a pipe member or the like. As a result, air can be supplied from the blower 4 to the surface layer portion 10 through the flow path portion 5. The seat cushion 2 is also assembled substantially in the same manner as the seat back 3, and the automobile seat 1 is assembled by being integrated via a reclining adjuster (not shown) that enables angle adjustment.

The embodiment configured as described above has the following effects. The spacer portion 30 is partially laminated on the rear side (opposite side to the seating surface) of the functional layer portion 20, and the flow path portion 5 is formed halfway in the thickness direction of the spacer portion 30 in the second step. As a result, the air supplied through the flow path portion 5 can be discharged from the seating surfaces of the back cover 3s and the cushion cover 2s. Further, since the spacer portion 30 can be made smaller than the case where the spacer portion 30 is arranged over the entire surface of the back cover 3s and the cushion cover 2s, the material cost can be reduced. In particular, since the spacer portion 30 is formed in a disk shape having a diameter slightly larger than the diameter of the flow path portion 5, the effect of reducing the material cost is great. Further, since the flow path portion 5 is formed by the drill 60 in the second step, the flow path portion 5 can be formed by a simple method. Further, since the thin-walled portion 3pa is formed in the portion of the cushion pad 2p and the back pad 3p that forms the flow path portion 5, it is necessary to provide the flow path portion 5 in the cushion pad 2p and the back pad 3p in the second step. It will be easy.

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, as shown in FIG. 3, the surface material 11 of the surface layer portion 10 is formed of a leather material provided with a plurality of small-diameter through holes 11a. However, the present invention is not limited to this, and as shown in FIG. 8, the surface material 11A of the surface layer portion 10A may be formed of a breathable fabric.

2. In the above embodiment, in the first step, the molding material M is put on the cavity surface 51a of the lower mold 51, and then the upper mold 52 is closed for foam molding. However, the present invention is not limited to this, and the molding material M may be injected into the cavity 53 through the injection hole with the upper mold 52 closed with respect to the lower mold 51.

3. 3. In the above embodiment, the present invention is applied to a seat of an automobile, but it may be applied to a seat mounted on an airplane, a ship, a train, or the like.

1 Automobile seat (vehicle seat)
2 Seat cushion 2p Cushion pad (pad body)
2s cushion cover (skin material)
2C cushion component (component)
3 Seat back 3p back pad (pad body)
3s back cover (skin material)
3C back component (component)
3pa Thin-walled part 4 Blower 5 Flow path part 10 Surface layer part 10A Surface layer part 20 Functional layer part 30 Spacer part 40 Intrusion prevention layer part 50 Molding mold 51 Lower mold 52 Upper mold 53 Cavity 60 Drill M Molding material

Claims (4)

A method for manufacturing a component member of a vehicle seat, in which a pad body as a cushion material and a skin material covering the pad body are integrated at the time of foam molding of the pad body.
A surface layer portion in which the skin material is arranged on the seating surface side and has breathability, a functional layer portion which is laminated on the side opposite to the seating surface of the surface layer portion and has breathability, and a seating surface of the functional layer portion. Invasion of the molding material of the pad body at the time of foam molding of the spacer portion having breathability partially laminated on the opposite side and the pad body laminated on the side opposite to the seating surface of the spacer portion and the functional layer portion. Has an intrusion prevention layer and
The first step of integrating the skin material and the pad body at the time of molding the pad body, and air can pass through the pad body and the intrusion prevention layer portion from the side opposite to the seating surface of the pad body. It has a second step of forming a smooth flow path, and has
A method for manufacturing a constituent member of a vehicle seat in which the flow path portion is formed halfway in the thickness direction of the spacer portion in the second step. The method for manufacturing a constituent member of a vehicle seat, wherein the spacer portion is provided corresponding to the flow path portion and is formed in a size that covers at least the entire cross section of the flow path portion in claim 1. The method for manufacturing a constituent member of a vehicle seat, wherein the formation of the flow path portion in the second step is performed by a drill according to claim 1 or 2. In any one of claims 1 to 3, the portion of the pad body forming the flow path portion has a concave shape toward the skin material on the side opposite to the seating surface of the pad body in the first step. A method for manufacturing a component of a vehicle seat on which a thin portion is formed.

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