JP2021165086A - Constitution member of vehicle seat and mold thereof - Google Patents

Abstract

To provide a seat constitution member and a mold of the seat constitution member in which a pad body is integrally foamed and molded with a skin material and the feeling of discomfort caused by a sewing line part on the skin material is suppressed.SOLUTION: In a cushion constitution member 10, a cushion pad 11 is integrally formed on a cushion cover 12. A top plate main part 12a and a top plate side part 12b in a plurality of pieces in which a surface layer part 12A and a foam layer part 12B constituting the cushion cover 12 are laminated are connected to one another with a sewing line L1. The top plate main part 12a includes a main part 12a1 and a main vertical wall part 12a2. The top plate side part 12b includes a side main part 12b1 and a side vertical wall part 12b2. A rear surface of the foam layer part 12B of the main part 12a1 and a rear surface of the foam layer part 12B of the main vertical wall part 12a2 intersect with each other to form an acute angle without any space therebetween. The rear surface of the foam layer part 12B of the side main part 12b1 and the rear surface of the foam layer part 12B of the side vertical wall part 12b2 intersect with each other to form an obtuse angle.SELECTED DRAWING: Figure 3

Description

The present invention relates to a constituent member of a vehicle seat and a molding mold thereof.

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. FIG. 7 shows a cross section of a part of the sheet constituent member 100. In the sheet constituent member 100, the first piece 111, which is one of the plurality of pieces forming the skin material 110, and the second piece 112 are sewn along the sewing line 113, and a pad made of urethane foam is sewn on the back surface side thereof. The body 120 is integrated by integral foam molding. The first piece 111 and the second piece 112 are formed by cutting from a layered body in which the fabric 110A and the urethane slab pad 110B are laminated. The first piece 111 and the second piece 112 have main portions 111a and 112a, and vertical wall portions 111b and 112b rising vertically from the main portions 111a and 112a, respectively. On the side of the urethane slab pads 110B of the corner portions 111c and 112c between the main portions 111a and 112a and the standing wall portions 111b and 112b, a part of the urethane slab pad 110B is recessed in the direction of the fabric 110A. Is formed. This is because the surface of the urethane slab pad 110B on the pad body 120 side is fitted in the direction of the fabric 110A in order to secure the cross-sectional peripheral length at the corner portions 111c and 112c. On the side of the skin material 110 opposite to the fabric 110A of the urethane slab pad 110B, a high-hardness impregnated layer 110C is formed in which a part of the raw material penetrates and solidifies in the process of integrally foam molding the pad body 120. .. A similar configuration is described in Patent Document 1.

JP-A-2017-81219

In the above-mentioned sheet constituent member 100, as shown in FIG. 7, the impregnated layer 110C is also formed on the urethane slab pads 110B of the fitting portions 111d and 112d of the skin material 110. The impregnated layer 110C has a higher hardness than the urethane slab pad 110B, and is arranged at a position closer to the fabric 110A than the main portions 111a and 112a in the fitting portions 111d and 112d. As a result, there is a problem that the occupant seated on the fabric 110A of the main portions 111a and 112a of the skin material 110 senses the corner portions 111c and 112c with a sense of discomfort. Therefore, as shown in FIG. 8, the resin tape 150 covering the fitting portions 111d and 112d to the standing wall portions 111b and 112b was attached. When the resin tape 150 is attached, the impregnated layer 110C is not formed on the urethane slab pad 110B at that portion, so that the occurrence of a sense of discomfort in hardness can be avoided, but there is a problem that the material cost increases.

In view of such a problem, an object of the present invention is to provide a seat constituent member and a molding die thereof, in which a pad body is integrally foam-molded with respect to the skin material and the discomfort of the sewing line portion of the skin material is suppressed.

The first invention of the present invention relates to a constituent 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. The skin material is formed by laminating a surface layer portion arranged on the seating surface side and a foam layer portion laminated on the side opposite to the seating surface of the surface layer portion. Further, the skin material is formed by integrating a plurality of pieces by sewing. Adjacent first and second pieces of the plurality of pieces are connected by a sewing line. The first piece has a first main portion constituting a seating surface and a first standing wall portion extending from the first main portion in a direction away from the seating surface. The second piece has a second main portion forming a seating surface and a second standing wall portion extending from the second main portion in a direction away from the seating surface. The sewing line is provided in a state where the first standing wall portion and the second standing wall portion face each other with the surface layer portions. The pad body-side surface of the foam layer portion of the first main portion and the pad body side surface of the foam layer portion of the first standing wall portion intersect at an acute angle without a gap. Further, the surface of the second main portion on the pad body side of the foam layer portion and the surface of the second standing wall portion of the foam layer portion on the pad body side intersect at an obtuse angle.

According to the first invention, the surface of the foam layer portion of the first main portion on the pad body side and the surface of the foam layer portion of the first standing wall portion on the pad body side intersect at an acute angle without a gap. In other words, between the foam layer portion of the first main portion and the foam layer portion of the first standing wall portion, the opening side of the fitting portion in which a part of the foam layer portion is recessed in the direction of the surface layer portion is closed. Further, since the foamed layer portion intersects the foamed layer portion of the second main portion and the foamed layer portion of the second standing wall portion at an obtuse angle, an fitting portion is not formed. As a result, the distance between the impregnated layer formed by invading and solidifying a part of the raw material in the process of integrally foam molding the pad body with respect to the foamed layer portion and the surface layer portion does not become too narrow, and the structure of the vehicle sheet is formed. It is possible to suppress deterioration of the feel of the member on the seating surface.

The second invention of the present invention relates to a molding mold for a constituent member of a vehicle seat in the first invention. The pad body has a lower mold in which the skin material is arranged so that the surface layer portion abuts on the mold surface, and the pad body has a surface shape opposite to the skin material and is closed with respect to the lower mold. It is provided with an upper mold for forming a cavity corresponding to the above. On the mold surface of the lower mold, a plate-shaped standing plate portion inserted between the first standing wall portion and the second standing wall portion has an acute angle with respect to the main mold surface that abuts on the first main portion. It is arranged so as to intersect with each other at an acute angle with respect to the main mold surface that abuts on the second main portion.

According to the second invention, the first main portion and the second main portion are brought into contact with the main mold surface of the lower mold, and the first standing wall portion and the second standing wall portion are brought into contact with each other so as to sandwich the standing plate portion. By closing the upper mold in this state and injecting a molding material for forming the pad body into the cavity, the constituent members of the vehicle seat can be molded.

It is a perspective view which looked at the car seat diagonally from the front. FIG. 1 is a cross-sectional view taken along the line II-II of the constituent members of the automobile seat shown in FIG. It is a figure which shows the part III of FIG. 2 enlarged. 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 a figure explaining the prior art. It is a figure explaining the prior art.

1 to 6 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, 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 (not shown) forming a skeleton, and a cushion component 10 mounted on the cushion frame. The cushion component 10 includes a cushion pad 11 which is a cushion material and a cushion cover 12 which is a skin material (see FIG. 2). The seat back 3 includes a back frame (not shown) forming a skeleton, a back pad (not shown) which is a cushioning material placed on the back frame, and a back cover which is a skin material covering the back pad. It has 3a and. Since the seat back 3 has a normal configuration, further description thereof will be omitted, and the cushion component 10 of the seat cushion 2 having a unique configuration will be described. Here, the cushion component 10, the cushion pad 11, and the cushion cover 12 correspond to the "component", "pad body", and "skin material" in the claims, respectively.

As shown in FIGS. 1 and 2, the cushion cover 12 is formed in a bag shape in which a plurality of pieces are integrated by sewing and open downward. Specifically, the cushion cover 12 is located on both the left and right sides of the top plate main portion 12a that supports the buttocks and the lower surface side of the thighs of the seated person, and mainly the buttocks and the large portion of the seated person. It has a top plate side portion 12b that supports the side surface side of the thigh portion. Further, the cushion cover 12 has a side portion 12c that covers the bank portion 11b of the cushion pad 11 that is located outside in the seat width direction of the left and right top plate side portions 12b and projects upward. The top plate main portion 12a and the top plate side portion 12b are sewn along a sewing line L1 extending substantially in the front-rear direction. The top plate side portion 12b and the side portion 12c are sewn on a sewing line L2 extending in the substantially front-rear direction. The top plate main portion 12a, the top plate side portion 12b, and the side portion 12c correspond to each piece. The top plate main portion 12a and the top plate side portion 12b correspond to the "first piece" and the "second piece" of the claims, respectively.

As shown in FIG. 3, the plurality of pieces constituting the cushion cover 12 are a surface layer portion 12A arranged on the front surface side and a foam layer portion arranged on the back surface side (the side opposite to the front surface side) of the surface layer portion 12A. 12B and 12B are formed by being cut from a laminated layered body. Specifically, as the surface layer portion 12A, a cloth such as a fabric, genuine leather, synthetic leather, or the like is preferably used. The foam layer portion 12B is made of slab urethane having ^{a low air permeability (about 1 to 10 cc / cm 2 · sec).} Foam layer portion 12B, high air permeability of the side surface portion 12A (200~400cc / cm about ² · sec) and a slab urethane, opposite side of the low air permeability of the surface layer portion 12A (1~10cc / cm ² · It may have a double structure in which slab urethane (about sec) is laminated. The foamed layer portion 12B prevents the molding material M (see FIG. 5) of the cushion pad 11 from reaching the surface layer portion 12A during foam molding of the cushion pad 11, and contributes to giving the cushion cover 12 a soft feel.

As shown in FIG. 2, the cushion pad 11 is a member forming the outer shape of the seat cushion 2, and the main portion 11a corresponding to the top plate main portion 12a and the top plate side portion 12b of the cushion cover 12, and the cushion cover 12 It has a bank portion 11b corresponding to the side portion 12c, and a bank portion 11b. The cushion pad 11 is made of polyurethane foam having a density of 10 to 60 kg / m ³ , and a non-woven fabric backing material 11c is integrally attached to the back surface side opposite to the cushion cover 12.

As shown in FIG. 3, the top plate main portion 12a includes a main main portion 12a1 forming a seating surface and a main standing wall portion 12a2 that rises diagonally downward at an acute angle with respect to the main main portion 12a1. It is formed. The top plate side portion 12b is formed with a side main portion 12b1 forming a seating surface and a side standing wall portion 12b2 that rises diagonally downward at an obtuse angle with respect to the side main portion 12b1. The main standing wall portion 12a2 and the side standing wall portion 12b2 are connected by sewing at a sewing line L1 in the vicinity of their tip portions.

At the corner portion 12a3 between the main main portion 12a1 and the main standing wall portion 12a2 in the top plate main portion 12a, the foam layer portion 12B of the main main portion 12a1 and the foam layer portion 12B of the main standing wall portion 12a2 are bent at an acute angle. Are in contact with each other. Then, between the foam layer portion 12B of the main main portion 12a1 and the foam layer portion 12B of the main standing wall portion 12a2, an fitting portion to be fitted in the direction of the surface layer portion 12A is not formed, and the surface layer portion 12A abuts without a gap. The contact line 12a4 is formed at a position separated from the contact line 12a4. As a result, the high-hardness impregnated layer 12C and the surface layer portion 12A formed by invading and solidifying a part of the molding material M, which is a raw material thereof, in the process of integrally foam molding the cushion pad 11 with respect to the foamed layer portion 12B. It is possible to suppress the deterioration of the tactile sensation on the seating surface without the interval becoming too narrow. Here, the main main portion 12a1 and the main standing wall portion 12a2 correspond to the "first main portion" and the "first standing wall portion" in the claims, respectively.

At the corner portion 12b3 between the side main portion 12b1 and the side standing wall portion 12b2 in the top plate side portion 12b, the foam layer portion 12B of the side main portion 12b1 and the foam layer portion 12B of the side standing wall portion 12b2 are bent at an obtuse angle. Are in contact with each other. The foam layer portion 12B of the side main portion 12b1 and the foam layer portion 12B of the side standing wall portion 12b2 do not form an fitting portion that smoothly and continuously fits in the direction of the surface layer portion 12A, and the thickness of the foam layer portion 12B. Is maintained. As a result, the distance between the impregnated layer 12C and the surface layer portion 12A is not too narrow, and it is possible to prevent the feeling on the seating surface from being deteriorated. Here, the side main portion 12b1 and the side standing wall portion 12b2 correspond to the "second main portion" and the "second standing wall portion" in the claims, respectively.

As shown in FIG. 2, the sewing line L2 in which the top plate side portion 12b and the side portion 12c are connected has the same configuration and has the same effect. Since the top plate main portion 12a in the sewing line L1 portion has only been replaced with the side portion 12c, the description thereof will be omitted. The terminal side of the side portion 12c is fixed to the back surface side of the cushion pad 11 by adhesion.

A method of manufacturing the cushion component 10 will be described with reference to FIGS. 4 to 6. The cushion component 10 is manufactured by molding the cushion pad 11 in the molding mold 20 and at the same time integrating it with the cushion cover 12. The molding die 20 has a lower die 21 and an upper die 22 that forms a cavity 23 having a shape that conforms to the shape of the cushion pad 11 when the lower die 21 is closed to the lower die 21.

The cavity surface 21a of the lower mold 21 is formed in a shape corresponding to the shape of the surface on the upper side (seat surface side) of the cushion pad 11. Then, the sewing line L1 of the cushion cover 12 is arranged at the apex portion thereof, and both sides are arranged so as to be sandwiched between the surface layer portion 12A of the main standing wall portion 12a2 and the surface layer portion 12A of the side standing wall portion 12b2. The standing plate portion 21a2 of the above is arranged. Specifically, the standing plate portion 21a2 is arranged so as to intersect the inner surface of the seat on the main mold surface 21a1, which is the surface corresponding to the upper side (seat surface side) of the cushion component 10 on the cavity surface 21a, at an acute angle. It is set up. Further, the standing plate portion 21a2 intersects with the outer surface of the seat on the main mold surface 21a1 (the surface with which the surface layer portion 12A of the side main portion 12b1 abuts when the cushion cover 12 is set on the lower mold 21) at an obtuse angle. It is arranged so as to. A standing plate portion 21a3 similar to the standing plate portion 21a2 is also arranged in a portion of the cushion cover 12 corresponding to the sewing line L2 so as to extend in the front-rear direction. The standing plate portion 21a3 is arranged so as to intersect the outer surface of the sheet on the main mold surface 21a1 at an acute angle. Further, the standing plate portion 21a3 intersects with the inner surface of the seat on the main mold surface 21a1 (the surface with which the surface layer portion 12A of the side main portion 12b1 abuts when the cushion cover 12 is set on the lower mold 21) at an obtuse angle. It is arranged so as to. The cavity surface 22a of the upper die 22 is formed in a shape corresponding to the shape of the surface on the lower side (opposite the seating surface) of the cushion pad 11.

As shown in FIG. 4, the cushion cover 12 is set so that the surface layer portion 12A of the cushion cover 12 abuts on the cavity surface 21a of the lower mold 21, and the backing material 11c is set on the cavity surface 22a of the upper mold 22. The cushion cover 12 is arranged so that the sewing line L1 is arranged at the apex of the standing plate portion 21a2 and both sides thereof are sandwiched between the surface layer portion 12A of the main standing wall portion 12a2 and the surface layer portion 12A of the side standing wall portion 12b2. The portion corresponding to the sewing line L2 is arranged with respect to the standing plate portion 21a3 in the same manner as the portion corresponding to the sewing line L1. At this time, since the left and right corner portions 12a3 are pressed against the base portion of the standing plate portion 21a2 by the main main portion 12a1, it is particularly necessary to temporarily fix the surface layer portion 12A of the cushion cover 12 to the cavity surface 21a by adhesive or the like. No. The same applies to the portion corresponding to the sewing line L2. The side portion 12c of the cushion cover 12 is folded back toward the outside of the seat from the middle and placed on the parting surface 21b.

Next, as shown in FIG. 5, the molding material M is injected onto the foam layer portion 12B of the cushion cover 12 arranged on the lower mold 21, and the upper mold 22 is closed with respect to the lower mold 21. At this time, a part of the side portion 12c of the cushion cover 12 is sandwiched between the parting surface 21b of the lower mold 21 and the parting surface 22b of the upper mold 22. The molding material M is filled in the cavity 23 while foaming and expanding, and is cured in that state as shown in FIG. 6, whereby the cushion pad 11 is molded and at the same time integrated with the cushion cover 12. At this time, a part of the molding material M is cured in a state of invading the foamed layer portion 12B to form a high hardness impregnated layer 12C. Further, the backing material 11c is also cured in a state where the molding material M has penetrated, and the backing material 11c is integrated with the cushion pad 11. In this state, the upper die 22 is opened with respect to the lower die 21, the cushion pad 11 integrated with the cushion cover 12 is taken out from the lower die 21, and the terminal side of the side portion 12c of the cushion cover 12 is the back surface of the cushion pad 11. The cushion component 10 is obtained by fixing to the side by adhesion.

The embodiment configured as described above has the following effects. The surface of the main main portion 12a1 on the foam layer portion 12B on the cushion pad 11 side and the surface of the main vertical wall portion 12a2 on the foam layer portion 12B on the cushion pad 11 side intersect at an acute angle without a gap. In other words, between the foam layer portion 12B of the main main portion 12a1 and the foam layer portion 12B of the main standing wall portion 12a2, the opening side of the fitting portion in which a part of the foam layer portion 12B is recessed in the direction of the surface layer portion 12A is It is closed. Further, between the foam layer portion 12B of the side main portion 12b1 and the foam layer portion 12B of the side standing wall portion 12b2, the foam layer portion 12B intersects at an obtuse angle, so that an fitting portion is not formed. As a result, the distance between the impregnated layer 12C formed by invading and solidifying a part of the molding material M in the process of integrally foam molding the cushion pad 11 with respect to the foamed layer portion 12B and the surface layer portion 12A does not become too narrow. It is possible to suppress deterioration of the tactile sensation on the seating surface of the cushion component 10.

Further, in the molding mold 20 of the cushion component 10, the main main portion 12a1 and the side main portion 12b1 are brought into contact with the main mold surface 21a1 of the lower mold 21, and the surface layer of the main standing wall portion 12a2 is sandwiched between the standing plate portions 21a2. The cushion cover 12 is arranged in a state where the portion 12A and the surface layer portion 12A of the side standing wall portion 12b2 are in contact with each other. At this time, since the left and right corner portions 12a3 are pressed against the base portion of the standing plate portion 21a2 by the main main portion 12a1, it is particularly necessary to temporarily fix the surface layer portion 12A of the cushion cover 12 to the cavity surface 21a by adhesive or the like. No. In this state, the cushion component 10 can be molded by injecting the molding material M that forms the cushion pad 11 into the cavity 23.

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, in the process shown in FIG. 5, the molding material M is put on the cushion cover 12 arranged on the cavity surface 21a of the lower mold 21, and then the upper mold 22 is closed and foam molded. .. However, the present invention is not limited to this, and the cushion cover 12 may be arranged in the lower mold 21, the upper mold 22 may be closed, and the molding material M may be injected into the cavity 23 through the injection hole in that state.

2. 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. Further, it may be applied to a seat mounted on an airplane, a ship, a train or the like.

1 Automotive seats (vehicle seats)
2 Seat cushion 10 Cushion component (component)
11 Cushion pad (pad body)
12 Cushion cover (skin material)
12a Top plate main part (1st piece)
12a1 Main main part (1st main part)
12a2 Main wall (1st wall)
12a3 Corner part 12b Top plate side part (2nd piece)
12b1 Side main part (2nd main part)
12b2 Side wall (2nd wall)
12b3 Corner part 12A Surface layer part 12B Foam layer part 12C Impregnation layer 20 Molding mold 21 Lower mold 21a Cavity surface 21a1 Main mold surface 21a2 Standing plate part 22 Upper mold 22a Cavity surface 23 Cavity L1 Sewing line M Molding material

Claims (2)

A component 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.
The skin material is composed of a surface layer portion arranged on the seating surface side and a foam layer portion laminated on the side opposite to the seating surface of the surface layer portion.
The skin material is formed by integrating a plurality of pieces by sewing.
Adjacent first and second pieces of the plurality of pieces are connected by a sewing line.
The first piece has a first main portion constituting a seating surface and a first standing wall portion extending from the first main portion in a direction away from the seating surface, and the second piece constitutes a seating surface. It has a main portion and a second standing wall portion extending in a direction away from the seating surface from the second main portion, and the first standing wall portion and the second standing wall portion are in a state where the surface layer portions face each other. There is a sewing line,
The pad body side surface of the foam layer portion of the first main portion and the pad body side surface of the foam layer portion of the first standing wall portion intersect at an acute angle without a gap.
A component member of a vehicle seat in which a surface on the pad body side of the foam layer portion of the second main portion and a surface on the pad body side of the foam layer portion of the second standing wall portion intersect at an obtuse angle. A molded mold for a component of a vehicle seat according to claim 1.
The pad body has a lower mold in which the skin material is arranged so that the surface layer portion abuts on the mold surface, and the pad body has a surface shape opposite to the skin material and is closed with respect to the lower mold. With an upper mold, which forms a cavity corresponding to
On the mold surface of the lower mold, a plate-shaped standing plate portion inserted between the first standing wall portion and the second standing wall portion has an acute angle with respect to the main mold surface that abuts on the first main portion. A molding mold for a constituent member of a vehicle seat, which is arranged so as to intersect with each other at an obtuse angle with respect to a main mold surface that abuts on the second main portion.

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