JP2764651B2 - Manufacturing method of integral foam sheet - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an integral foam sheet in which a seat pad formed by integral foaming with a seat frame is covered with a trim cover.

[Conventional technology]

For example, a seat pad made of an elastic body or the like is supported by a seat frame support member or the like, and the seat frame and the seat pad are covered with a trim cover made of a skin or the like to form a seat cushion or a seat back of a seat of a vehicle or the like. ing.

The seat pad is formed, for example, by a seat pad forming die (die). The mold includes, for example, a pair of an upper mold and a lower mold, and a foam material such as urethane foam is poured into a cavity having a predetermined shape defined between the upper mold and the lower mold, and cured to form a seat pad. Is formed into a corresponding shape.

Here, as a seat back of a seat of an automobile or the like, for example, a configuration using a seat pad formed by so-called integral foaming, in which a foaming material is poured into a cavity of a mold in which a seat frame is arranged and cured together with the seat frame. It has been known. A sheet (seat back) having such a configuration is called, for example, an integral foam sheet. The integral foam sheet is formed by covering a seat pad formed by integral foam with a trim cover made of a skin or the like.

According to the integral foam sheet having such a configuration, the displacement of the seat pad with respect to the seat frame is prevented, and the configuration of the seat itself, the work process, and the like can be simplified.

[Problems to be solved by the invention]

Here, for example, when the occupant is seated, the seat frame is provided with a support member that prevents the upper body of the occupant from moving backward and provides appropriate elasticity to the upper body of the occupant. As a support member, for example, an S-spring that is installed and stretched using a retaining member such as a retainer between left and right sides of a seat frame is widely used.

However, in a known method, the foam material of the seat pad impregnates a support member such as an S-spring and is cured in a state of impregnation. That is, since the foam material of the seat pad is hardened around the support member, even if a load from the occupant acts on the support member via the seat pad, the deflection of the support member to the rear is restricted by the seat pad. In addition, the elasticity of the support member is impaired.

Here, in the part other than the lumbar vertebra (non-lumbar vertebrae) in the state of the occupant, not much elasticity is required, so that even under the elasticity of the impregnated S-spring, there is no adverse effect on the occupant. .

However, in the support member (lumbar support member) that supports the lumbar portion of the seated person, if the elasticity of the support member such as the S-spring is impaired, the pressure (lumbar support force) suitable for supporting the lumbar spine of the seated person is increased. Not available from the lumbar support member. Therefore, there is a possibility that the sense of stability of the sitting posture is reduced and the seated person is discomforted.

In addition, it is generally known that the lumbar spine of a seated person can be reduced in fatigue accumulated in the lumbar vertebra by pressing and supporting the lumbar vertebra under an appropriate pressure, that is, an appropriate lumbar support force. . However, in known integral foam sheets,
Since an appropriate lumbar support force does not act on the lumbar portion of the seated person, fatigue of the lumbar spine is not alleviated, and accumulation of fatigue is inevitable.

Here, for example, in the case of an S spring, it is conceivable to reduce the wire diameter of the S spring so that the lumbar support member is easily bent. However, if the wire diameter of the S-spring is reduced, the spring constant of the S-spring decreases, so that a lumbar support force suitable for pressing the lumbar vertebra of the seated person cannot be obtained.

An object of the present invention is to provide a method of manufacturing an integral foam sheet capable of pressing and supporting a lumbar vertebra of a seated person with an appropriate lumbar vertebra support force.

[Means for solving the problem]

In order to achieve this object, according to the present invention, a locking member to which a lumbar support member can be attached is previously fixed to a corresponding portion of a frame main body forming a seat frame, and a seat pad is attached to the seat frame. Has a concave portion adjacent to the locking member on the back surface, and is formed by integral foaming with a seat pad.

After integral foaming of the seat pad, the elastic lumbar support member is attached to the seat frame from the recess on the back surface of the seat pad, and the seat pad is covered with the trim cover to form an integral foam sheet.

〔Example〕

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

According to the method for manufacturing an integral foam sheet according to the present invention,
As shown in FIG. 1, a recess 12 is formed in a portion corresponding to the lumbar vertebra of the seated person on the back surface 10a of the seat pad 10, and after the seat pad is integrally foamed, the lumbar vertebrae of the support member 16 of the seat frame 14 are formed. The support member 16a is attached.

The seat frame 14 includes, for example, a frame main body 18 formed by bending a substantially rectangular shape such as a pipe, and a support member 16 for supporting the seat pad 10 is provided between the left and right sides of the frame main body. It is provided in. The support member 16 includes, for example, a lumbar support member 16a that supports a lumbar vertebra of a seated person and a non-lumbar support member 16b that supports a portion other than the lumbar vertebra (non-lumbar portion) of the upper body. Each is arranged in the corresponding part.

As the non-lumbar support member 16b, for example, the frame body 1
An elastic plate erected and fixed between the left and right sides of the seat pad 8 can be used, and the elastic plate restricts the backward movement of the seat pad 10 due to the load on the non-lumbar spine portion of the occupant.

As can be seen from FIG. 2 in addition to FIG. 1, a locking member capable of locking the lumbar support member 16a, which will be described later, for example, a retainer 22 is provided at a portion corresponding to the lumbar vertebra of the seated person. Are fixed to the left and right sides of the frame body 18, respectively.

The seat pad 10 is formed by, for example, an integral foaming mold 24. As shown in FIG. 3, the mold (mold for integral foaming) 24 includes, for example, a pair of an upper mold 24a and a lower mold 24b, and a cavity 26 corresponding to the shape of the sheet pad 10.
Is defined between the upper mold and the lower mold. And the cavity
The seat pad 24 is placed at a predetermined position in 26, a foam material is poured into the cavity, and the foam material is cured together with the seat frame, whereby the seat pad 10 is foamed and formed into a predetermined shape.

At this time, as can be clearly seen from FIGS. 1 to 3, for example, the concave portion 12 corresponds to the lumbar vertebra of the seated person due to the protrusion 28 into the cavity 26 formed in the lower mold 24b of the mold. Is formed on the back surface 10a of the seat pad. The recess 12 is formed as a space adjacent to the retainer 22 of the frame body, and the lumbar support member 16a is attached to the retainer from the recess. A spring member, for example, an S-spring as shown in FIG. 1 can be used as the lumbar support member 16a. As can be seen from FIG. 2 in addition to FIG.
The spring (lumbar support member) 16a is extended and stretched between the left and right sides of the frame body 18 at a position corresponding to the lumbar spine of the seated person by locking both ends to the retainers 22 on the left and right sides, respectively. Under such elasticity, the seat pad 10 of the lumbar vertebra part of the seated person can be pressed.

Then, as shown in FIG. 2, after the S-spring 16a is attached, the seat pad 10 is covered with a trim cover 30 made of, for example, a skin, thereby forming an integral foam sheet 32.
Is completed.

As described above, according to the manufacturing method of the integral foam sheet of the present invention, after the sheet pad 10 is integrally foamed, the S spring 16a is formed by utilizing the concave portion 12 formed on the back surface 10a of the seat pad.
However, it is attached to a position where the lumbar spine of the seated person can be pressed and supported. That is, the foam material of the seat pad 10 is the S spring 16a.
Is not impregnated, and the rear of the S spring is the space of the concave portion 12, so that when the load of the occupant acts on the lumbar portion from the seating surface of the seat pad, the S spring sufficiently bends under its own elasticity. . Therefore, the lumbar spine of the seated person is
It can be pressed and supported under an appropriate pressure (lumbar support force) from the user, and does not give a discomfort to the occupant, thereby improving the comfort of the occupant.

Further, since the lumbar spine of the seated person is pressed and supported by an appropriate lumbar support force from the S spring 16a, fatigue of the seated person can be reduced.

Further, the S spring is provided with sufficient elasticity without reducing the wire diameter of the S spring 16a. Therefore, the lumbar spine of the seated person can be pressed and supported under an appropriate pressure, and in this respect, the comfort of the seated person is also ensured.

Further, the S spring 16a may be engaged with the retainer 22 of the frame main body from the concave portion 12 of the seat pad back surface 10a. Therefore, the mounting work of the S-spring 16a can be easily performed, and the operation process is not complicated and the configuration is not complicated.

In the embodiment, the non-lumbar support member 16b of the support member 16 is embodied as an elastic plate that is installed and fixed between the left and right sides of the frame body 18. But,
The present invention is not limited to this, and a configuration may be used in which a spring member such as an S-spring is used as the non-lumbar spine support member 16b, for example, like the lumbar spine support member 16a.

However, not much elasticity is required in portions other than the lumbar spine of the upper body of the seated person, and even when a spring member such as an S spring is provided as the non-lumbar vertebra support member 16b, the foaming of the seat pad 10 can be prevented. Wood impregnated,
The deflection of the spring member is regulated. Therefore, it is preferable to use an elastic plate as the non-lumbar support member 21.

The lumbar support member 16a is embodied as an S-spring, but presses the lumbar vertebra of the seated person under appropriate pressure.
Anything that can be supported is sufficient. Therefore, the lumbar support member 16a is not limited to the S-spring, and may be configured to use another spring member, for example, a band-shaped spring, a coil spring, or the like.

Further, the locking member 22 provided on the seat frame 14 is embodied as a retainer capable of locking the terminal of the S spring 16a, but is not limited to this. For example, a locking member having another configuration may be used. It is good also as a structure which performs.

Here, as the lumbar support member 16a, for example, a lumbar support device capable of adjusting the lumbar support force of the seated person may be provided in addition to a spring member such as an S spring. In the seat pad 10 of the present invention, the concave portion 12 is formed on the back surface 10a.
Is formed, there is no need to separately provide a mounting space for the lumbar support device, and the configuration is not complicated, and the workability is not reduced.

By the way, in the embodiment, the lumbar support member 16a and the non-lumbar support member 16b are illustrated as a configuration provided by two each, but the number of the lumbar support member, the non-lumbar support member and the like are not limited thereto. .

Although the method for producing an integral foam sheet of the present invention is suitable for producing a sheet for an automobile or the like, the present invention is not limited to this, and may be applied to other sheets, for example, an integral foam sheet for a train, an airplane, a ship, or the like. it can.

Further, the present invention is not limited to the vehicle seat, and may be applied to, for example, a seat of a conference room, a movie theater, etc., a head, a sofa, and the like.

The embodiments described above are intended to explain the present invention, and do not limit the present invention in any way. All modifications and alterations within the technical scope of the present invention are included in the present invention. Needless to say.

〔The invention's effect〕

As described above, according to the method for manufacturing an integral foam sheet according to the present invention, the lumbar support member of the support member is attached after integral foaming of the seat pad, so that the foam material of the seat pad impregnates the lumbar support member. It is cured without. Therefore, the lumbar support member flexes sufficiently under its own elasticity, and the lumbar vertebra of the seated person is pressed and supported under appropriate pressure from the lumbar support member. Therefore, the occupant does not feel uncomfortable, the occupant's fatigue is reduced, and the occupant's comfort is sufficiently improved.

In addition, the lumbar support member may be locked to the locking member of the frame main body from the concave portion on the back surface of the seat pad. for that reason,
The operation of attaching the lumbar support member can be easily performed, and the operation steps are not complicated and the configuration is not complicated.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic exploded perspective view of an integral foam sheet before attaching a lumbar support member. FIG. 2 is a cross-sectional view taken along line II-II of FIG. Fig. 2 is a sectional view of the integral foaming mold at a position corresponding to line II-II in Fig. 1. 10: seat pad, 12: recess, 14: seat frame, 16: support member, 16a: lumbar support member (S spring), 16b: non-lumbar support member (elastic plate), 22: retainer (locking member), 30 :
Trim cover, 32: integral foam sheet.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29L 31:58

Claims (1)

(57) [Claims] 1. A method for manufacturing an integral foamed sheet for covering a seat pad formed by integral foaming with a seat frame with a trim cover, comprising: a lumbar vertebra supporting a lumbar vertebra of a seated person among support members for supporting the seat pad. A locking member to which the support member can be attached,
The seat pad is previously fixed to a corresponding portion of the frame body forming the seat frame, and the seat pad has a concave portion adjacent to the locking member of the seat frame on the back surface, and is formed by integral foaming with the seat frame, After integral foaming of the pad, a support member having elasticity,
A method of manufacturing an integral foam sheet, wherein the sheet pad is attached to a seat frame from a recess on the back surface of the seat pad using a locking member, and the seat pad is covered with a trim cover.