JP4134039B2 - Cushion pad for seat and manufacturing method thereof - Google Patents

Cushion pad for seat and manufacturing method thereof Download PDF

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JP4134039B2
JP4134039B2 JP2004544723A JP2004544723A JP4134039B2 JP 4134039 B2 JP4134039 B2 JP 4134039B2 JP 2004544723 A JP2004544723 A JP 2004544723A JP 2004544723 A JP2004544723 A JP 2004544723A JP 4134039 B2 JP4134039 B2 JP 4134039B2
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layer
foam layer
slit
cushion pad
foam
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JPWO2004034853A1 (en
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雅信 坂野
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Toyo Tire Corp
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Toyo Tire and Rubber Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/18—Seat parts having foamed material included in cushioning part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B29C44/083—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another
    • B29C44/086—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another and feeding more material into the enlarged cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Description

本発明は、主として自動車等のシート用クッションパッド及びその製造方法に関するものである。  The present invention mainly relates to a cushion pad for a seat of an automobile or the like and a manufacturing method thereof.

例えば、自動車用シートは、発泡ウレタン等の樹脂発泡層を素材とするクッションパッドに布等の表皮材を被せて構成されている。
この種のクッションパッドにおいて、座り心地や乗り心地等の向上を目的として、例えば、硬度の異なる２種の発泡ウレタン等の樹脂発泡層を、直接あるいは薄いシート状の補強層を介在させて積層した積層構造のパッドが提案されている。
この積層構造のクッションパッドは、通常、パッド表面を成形する下型と、該下型に対しそれぞれ開閉自在な表層用の第１の上型及び裏層用の第２の上型を備えてなる成形型を用い、先ず、表層としての第１の発泡層を成形し、その後、支持材への取付側になる裏層（下層）としての第２の発泡層を成形して積層することにより製造される（例えば、特開昭６２−２４００９１号公報、特開昭６３−１２０６１０号公報）。
かかるクッションパッドにおいて、表皮材を装着する手段としては、クッションパッドにスリットを形成するとともに、該スリットの溝底近傍にスリットワイヤと称する棒状の係止部材を埋設配置しておいて、該係止部材に対して表皮材に取着された係止手段を係止して固定し、これにより縫製された表皮材の端縁部もしくは縫合部を前記スリットの部分に挟み込んで装着するのが一般的である。
ところで、前記の積層構造のクッションパッドにおいては、表皮材を装着するためのスリット及びワイヤ等の係止部材が、表層となる第１の発泡層に設けられている。例えば、図１１に示すように、第１の発泡層４１の表面における座部等の中央部４１ａと、両側部４１ｂ，４１ｂとの間に表皮材装着用スリット４３が形成されるとともに、該スリット４３の溝底４３ａの近傍に前記係止部材４５が埋設されている。
この埋設構造において、前記係止部材４５の埋込み代は、前記第２の発泡層４２との接合面との間には少なくとも１０ｍｍ、また前記スリット４３の溝底４３ａとの間には少なくとも５ｍｍは必要とされている。また、成形時における型内での液流れ性を確保し、発泡層の均質性を確保する必要がある。そのため、スリット４３の深さは第１の発泡層４１の厚みによって制限されることになる。
例えば、図１２のように、前記第１の発泡層４１と第２の発泡層４２とが比較的平坦な面で接合され積層されているもので、前記第１の発泡層４１の厚みｔが２５ｍｍのものにおいて前記の係止部材４５を第１の発泡層４１に埋設する場合、該発泡層４１と前記第２の発泡層４２との接合面４６に対する前記係止部材４５の埋込み代ｃとして最低１０ｍｍを、また前記溝底４３ａに対する前記係止部材４５の埋込み代ａとして最低５ｍｍをそれぞれ確保しようとすれば、前記スリット４３の深さｂは１０ｍｍになってしまう。従って、第１の発泡層４１の厚みｔを薄くした場合には、深溝のスリットを設定することができない。
一方、使用者からはシートの外観的な見栄え向上等のために、スリット４３の深溝感を出すことが強く要求されているが、前記のようにスリット深さが制限されることからその要求に応えられないのが実情である。
本発明は、上記に鑑みてなしたものであり、積層構造のクッションパッドとして、各発泡層の厚み配分と、表皮材装着用のスリットの深さの設定の自由度が高く、第１の発泡層の厚みを薄くしても、スリットワイヤ等の係止部材の抜けを防止できる充分な埋込み代を確保して、しかも深溝のスリットを設定することができる、シート用クッションパッドを提供するものであり、さらにはこのクッションバッドを従来と同様の発泡成形により容易に得ることができる製造方法を提供するものである。For example, an automobile seat is configured by covering a cushion pad made of a resin foam layer such as urethane foam with a skin material such as cloth.
In this type of cushion pad, for example, two types of resin foam layers such as urethane foam having different hardness are laminated directly or with a thin sheet-like reinforcing layer interposed for the purpose of improving sitting comfort and riding comfort. A laminated pad has been proposed.
The cushion pad of this laminated structure usually comprises a lower mold for molding the pad surface, a first upper mold for the surface layer and a second upper mold for the back layer that can be opened and closed with respect to the lower mold, respectively. Manufactured by first molding a first foam layer as a surface layer using a mold, and then molding and laminating a second foam layer as a back layer (lower layer) to be attached to a support material. (For example, Japanese Patent Laid-Open Nos. 62-240091 and 63-120610).
In such a cushion pad, as a means for attaching the skin material, a slit is formed in the cushion pad, and a rod-shaped locking member called a slit wire is embedded in the vicinity of the groove bottom of the slit, and the locking is performed. The locking means attached to the skin material is locked and fixed to the member, and the edge portion or stitched portion of the skin material thus sewn is sandwiched between the slit portions and attached. It is.
By the way, in the cushion pad of the said laminated structure, locking members, such as a slit and a wire for mounting | wearing a skin material, are provided in the 1st foam layer used as surface layer. For example, as shown in FIG. 11, a skin material mounting slit 43 is formed between a central portion 41a such as a seat portion on the surface of the first foam layer 41 and both side portions 41b and 41b, and the slit The locking member 45 is embedded in the vicinity of the groove bottom 43 a of 43.
In this burying structure, the burying allowance of the locking member 45 is at least 10 mm between the joint surface with the second foamed layer 42 and at least 5 mm between the groove bottom 43 a of the slit 43. is needed. In addition, it is necessary to ensure liquid flowability in the mold during molding and to ensure the homogeneity of the foam layer. Therefore, the depth of the slit 43 is limited by the thickness of the first foam layer 41.
For example, as shown in FIG. 12, the first foam layer 41 and the second foam layer 42 are joined and laminated on a relatively flat surface, and the thickness t of the first foam layer 41 is In the case of embedding the locking member 45 in the first foam layer 41 in the case of 25 mm, as the embedding margin c of the locking member 45 to the joint surface 46 between the foam layer 41 and the second foam layer 42 If an attempt is made to secure a minimum of 10 mm and a minimum allowance of 5 mm as the embedding margin a of the locking member 45 to the groove bottom 43a, the depth b of the slit 43 will be 10 mm. Therefore, when the thickness t of the first foam layer 41 is reduced, a deep groove slit cannot be set.
On the other hand, the user is strongly required to give a deep groove feeling of the slit 43 in order to improve the appearance of the sheet, but the requirement for the slit depth is limited as described above. The reality is that we cannot respond.
The present invention has been made in view of the above, and as a cushion pad of a laminated structure, the degree of freedom in setting the thickness distribution of each foam layer and the depth of the slit for attaching the skin material is high, and the first foam To provide a cushion pad for a seat that can secure a sufficient burying allowance to prevent a locking member such as a slit wire from coming off even if the layer thickness is thin, and can set a slit in a deep groove. Furthermore, the present invention provides a manufacturing method in which this cushion pad can be easily obtained by foam molding similar to the conventional one.

本発明は、硬度の異なる２種の樹脂発泡層を積層した積層構造をなし、表層としての第１の発泡層に、表皮材装着用のスリットが形成され、該スリットの溝底近傍に棒状の係止部材が埋設されてなるクッションパッドであって、前記第１の発泡層は、前記スリット形成部位における裏面側が、その裏面に接合される第２の発泡層側への膨らみ形状をなすように成形されており、この膨らみ部分により前記係止部材が所定以上の埋込み代を保有して埋設されていることを特徴とするものである。
このシート用クッションパッドによれば、表層である第１の発泡層におけるスリット形成部位の裏面側が膨らみ形状をなしているため、この膨らみ部分の厚みを利用して、スリット深さを深く設定することが可能になり、第１の発泡層の全体の厚みを大きくしなくても、係止部材の抜け防止のために必要な埋込み代を確保することができる。
したがって、前記の第１の発泡層の膨らみ部分を有することにより、第１の発泡層と第２の発泡層の厚み配分、スリットの深さを、それぞれ任意に設定でき、その設定の自由度を高めることができる。
前記係止部材が、前記第２の発泡層との接合面との間には少なくとも１０ｍｍの埋込み代、スリットの溝底との間には少なくとも５ｍｍの埋込み代を、それぞれ保有して埋設されているのが好ましく、これにより、前記のようにスリット深さを深く設定した場合にも、係止部材の抜けを確実に防止できる。
本発明は、前記のシート用クッションパッドを製造する方法として、パッド表面を成形する下型と、該下型に対しそれぞれ開閉自在な表層用の第１の上型及び裏層用の第２の上型を備えてなる成形型を用い、表層としての第１の発泡層と、その裏面に接合される裏層としての第２の発泡層とを順次発泡成形して積層するとともに、前記第１の発泡層に、表皮材装着用のスリットを形成し、該スリットの溝底近傍に棒状の係止部材を埋設する、クッションパッドの製造方法において、前記第１の上型の前記スリット形成部位の裏面側に相当する部分を、型閉じ状態において下型内に配置されるスリット形成片及び係止部材を迂回する上方への膨出形状をなすように形成しておき、前記下型に第１の発泡樹脂原液を注入し前記第１の上型を閉じて前記第１の発泡層を発泡成形する際、前記第１の上型により、第１の発泡層の前記スリット形成部位の裏面側を上方に膨らみを持たせるように成形することを特徴とする。
これにより、従来と同様の成形工程において、第１の発泡層の前記スリット形成部位の裏面側に膨らみを持たせることができる。そして、この第１の発泡層の上に、従来と同様にして第２の発泡層を発泡成形して積層することにより、上記した特徴を有する積層構造のクッションパッドを容易に得ることができる。The present invention has a laminated structure in which two types of resin foam layers having different hardnesses are laminated, and a slit for attaching a skin material is formed in the first foam layer as the surface layer, and a rod-like shape is formed near the groove bottom of the slit. It is a cushion pad in which a locking member is embedded, and the first foam layer is formed such that the back surface side of the slit forming portion forms a bulge shape toward the second foam layer side joined to the back surface. The locking member is molded and embedded with a predetermined or larger embedding allowance.
According to this cushion pad for seats, since the back surface side of the slit forming portion in the first foam layer as the surface layer has a bulging shape, the slit depth should be set deep using the thickness of the bulging portion. This makes it possible to secure an embedding allowance necessary to prevent the locking member from coming off without increasing the overall thickness of the first foam layer.
Therefore, by having the bulging portion of the first foam layer, the thickness distribution of the first foam layer and the second foam layer and the depth of the slit can be arbitrarily set, and the degree of freedom of the setting can be set. Can be increased.
The locking member is embedded with an embedding allowance of at least 10 mm between the joint surface with the second foam layer and an embedding allowance of at least 5 mm between the groove bottom of the slit. Thus, even when the slit depth is set deep as described above, it is possible to reliably prevent the locking member from coming off.
According to the present invention, as a method of manufacturing the cushion pad for a seat, the lower mold for forming the pad surface, the first upper mold for the surface layer that can be opened and closed with respect to the lower mold, and the second for the back layer, Using a mold having an upper mold, a first foam layer as a surface layer and a second foam layer as a back layer joined to the back surface are sequentially foam-molded and laminated, and the first In the cushion pad manufacturing method, a slit for attaching a skin material is formed in the foam layer, and a rod-shaped locking member is embedded in the vicinity of the groove bottom of the slit. A portion corresponding to the back surface side is formed so as to form an upward bulging shape that bypasses the slit forming piece and the locking member disposed in the lower mold in the mold closed state. Inject the foam resin stock solution and close the first upper mold. When foam molding the serial first foam layer by said first upper die, characterized by shaping the back surface side of the slit forming portion of the first foam layer so as to have a bulge upward.
Thereby, it can give a bulge to the back surface side of the said slit formation site | part of a 1st foaming layer in the formation process similar to the past. Then, a cushion pad having a laminated structure having the above-described characteristics can be easily obtained by foam-molding and laminating the second foam layer on the first foam layer in the same manner as in the past.

図１は、本発明に係るクッションパッドの第１の実施例を示す断面図である。
図２は、同上のクッションパッドの一部の拡大断面図である。
図３は、同上のクッションパッドを製造する成形型の概略断面図である。
図４は、同上の成形型による第１の発泡層の発泡成形状態を示す図３とは直角方向の断面における一部の拡大断面図である。
図５は、同上の成形型による第２の発泡層の発泡成形状態を示す一部の拡大断面図である。
図６は、本発明に係るクッションパッドの第２の実施例を示す断面図である。
図７は、同上のクッションパッドの一部の拡大断面図である。
図８は、同上のクッションパッドを製造する成形型の下型と第１の上型と第２の上型をそれぞれ分離して示す一部の断面図である。
図９は、同上の成形型による第１の発泡層の発泡成形状態を示す一部の断面図である。
図１０は、同上の成形型による第２の発泡層の発泡成形状態を示す一部の断面図である。
図１１は、従来のクッションパッドを例示する断面図である。
図１２は、同上の一部の拡大断面図である。
図１３は、従来のクッションパッドの他の例を示す断面図である。
図１４は、同上のクッションパッドを製造する従来の成形型による成形時の一部の断面説明図である。FIG. 1 is a cross-sectional view showing a first embodiment of a cushion pad according to the present invention.
FIG. 2 is an enlarged cross-sectional view of a part of the same cushion pad.
FIG. 3 is a schematic cross-sectional view of a mold for producing the same cushion pad.
FIG. 4 is an enlarged cross-sectional view of a part of the cross section in the direction perpendicular to FIG.
FIG. 5 is a partial enlarged cross-sectional view showing a foamed state of the second foam layer by the same mold.
FIG. 6 is a cross-sectional view showing a second embodiment of the cushion pad according to the present invention.
FIG. 7 is an enlarged cross-sectional view of a part of the same cushion pad.
FIG. 8 is a partial cross-sectional view showing the lower mold, the first upper mold, and the second upper mold for producing the cushion pad according to the present invention separately.
FIG. 9 is a partial cross-sectional view showing a foamed state of the first foam layer by the same mold.
FIG. 10 is a partial cross-sectional view showing a foamed state of the second foamed layer by the same mold.
FIG. 11 is a cross-sectional view illustrating a conventional cushion pad.
FIG. 12 is an enlarged sectional view of a part of the above.
FIG. 13 is a cross-sectional view showing another example of a conventional cushion pad.
FIG. 14 is a partial cross-sectional explanatory view at the time of molding by a conventional mold for manufacturing the cushion pad same as above.

次に本発明の実施の形態を図面に基づいて説明するが、本発明はこれに限定されるものではない。
図１は、本発明に係るクッションパッドの第１の実施例を示す断面図、図２は同クッションパッドの一部の拡大断面図である。
本発明に係るシート用のクッションパッドＡ１は、硬度の異なる２種の発泡ウレタン等の樹脂発泡層よりなり、図に示すように、使用者との対接側になる表層としての第１の発泡層１と、この第１の発泡層１よりも密度が高くてやや硬く、該第１の発泡層１の裏面に接合される裏層（下層）としての第２の発泡層２とが積層されてなる。図中の１ａはパッド表面における座部となる中央部、１ｂ，１ｂは前記中央部１ａよりやや高く盛り上がった両側部を示す。
前記表層としての第１の発泡層１には、パッド表面側の所要の箇所、例えば前記の中央部１ａと両側部１ｂ，１ｂとの間に、表皮材装着用のスリット３が形成され、さらに前記スリット３の溝底近傍にスリットワイヤと称する棒状の係止部材５が埋設配置されており、布地やレザー等の表皮材（図示せず）の端部に有する係止手段を係止することにより、前記スリットに挟み込んだ状態に装着できるようになっている。
前記第１の発泡層１は、前記第２の発泡層２との接合面６が前記スリット形成部位の裏面側において第２の発泡層２側への膨らみ形状をなすように成形されている。すなわち、前記接合面６は、前記スリット形成部位の裏面側で従来形状の接合面位置６ａ（仮想線で示す）よりも第２の発泡層２側へ凹入する曲線凸形状をなすように成形されている。そして、この凸形の膨らみ部分７により、前記スリット３の深さｂを、前記従来形状の接合面位置６ａの近くまで、あるいは該位置よりも深く形成した場合にも、該スリット３の溝底３ａと前記接合面６との間に所要の間隔を保有して、この部分に埋設される係止部材５が所定以上の埋込み代を保有できるように形成されている。
前記係止部材５の前記接合面６に対する埋込み代ｃは少なくとも１０ｍｍ、また前記溝底３ａに対する埋込み代ａは少なくとも５ｍｍを保有するように、前記膨らみ部分７の高さを設定しておくのがよく、これにより係止部材５の抜けを確実に防止できる。
なお、前記の第１の発泡層１の前記接合面６の膨らみ部分７の形状は、図のような曲線をなすものが好ましいが、断面略台形状等の角張った膨らみ形状をなすものであってもよい。
いずれにしても、前記第１の発泡層１の裏面に積層される第２の発泡層２については、前記膨らみ部分７の形状に対応した凹入形状をなして第１の発泡層１の裏面に全面的に接合され積層一体化される。
前記のクッションパッドＡ１の製造方法について、その製造に使用する装置と共に以下に説明する。
図３は、前記の積層構造のクッションパッドＡ１を成形する成形型の概略を示しており、図４及び図５はそれぞれ同上の成形型による第１の発泡層と第２の発泡層の発泡成形状態を示している。
成形型は、前記クッションパッドＡ１の表裏を反転した状態で成形するものであり、凹形状をなす下型１０と、該下型に対し開閉可能な二つの上型、すなわち表層用の第１の上型１１と、裏層用の第２の上型１２とを備えてなる。各型は、それぞれアルミニウム等の金属材から形成されている。
前記下型１０は、パッド表面を成形するものであり、その型内に、表皮材装着用のスリット３を形成するためのスリット形成片１３が突設されるとともに、発泡体内部に埋設される係止部材５を脱着可能に固定支持するための固定支持部（図示省略）が設けられている。例えば図１のように座部となる中央部１ａと、両側部１ｂ，１ｂとの間に、スリット３及び係止部材５を設ける場合、該位置に相当する型内の位置に前記スリット形成片及び固定支持部が配設される。
前記第１の上型１１と第２の上型１２とは、それぞれ前記下型１０に対しヒンジ結合されて、交互に型閉じ、型開きできるようになっており、第１の上型１１を型閉じした状態で表層としての第１の発泡層１を、また第２の上型１２を型閉じした状態で第２の発泡層２を成形するもので、両発泡層１、２を順次発泡成形することにより積層一体化できるようになっている。図中の１４ａ、１４ｂはそれぞれヒンジ結合部を示す。なお、前記両上型１１，１２の開閉のための機構は、従来と同じものを利用できるので、これらの図示説明は省略する。
本発明において使用する成形型の前記第１の上型１１は、前記スリット形成部位の裏面側に相当する部分が、前記下型１０に対して型閉じした状態において該下型１０内に配置されている前記スリット形成片１３及び係止部材５を迂回するように上方へ曲線凸形状に膨出した形状をなしている。１７は該第１の上型１１の膨出部を示し、上記した第１の発泡層１の膨らみ部分７の形状に対応する。
前記の成形型によりクッションパッドを成形する場合、従来と同様の手順で成形する。先ず、加熱調整された型を開いて、ワイヤ等の係止部材５を固定支持した状態において、下型１０の上に、第１の発泡層に適合するように配合した発泡樹脂原液、特にはウレタン原液を注入ヘッド２０により所要量注入する。そして前記第１の上型１１を閉じて、図４のように発泡成形を行い、発泡体中に前記スリット形成片１３及び前記係止部材５を埋設した状態で第１の発泡層１を成形する。また、前記第１の上型１１の前記スリット形成部位の裏面側に相当する部分が上方へ膨出した形状をなしているため、前記第１の発泡層１の前記スリット形成部位の裏面側に膨らみ部分７が形成され、この膨らみ部分７に前記係止部材５が埋設される。この膨らみ部分７の高さや形状は、前記第１の上型１１の膨出部１７によって決定される。従って、該膨出部１７の高さを適宜設定することにより、任意の高さや形状の膨らみ部分７を形成できる。
この後、前記第１の上型１１を開いて、前記第１の発泡層１の上に、第２の発泡層に適合するように配合した発泡樹脂原液、例えばウレタン原液を所要量注入し、前記第２の上型１２を閉じ、図５のように第２の発泡層２を発泡成形し、第１の発泡層１と接合一体化させる。すなわち、第２の発泡層２は、前記第１の発泡層１の裏面側の前記膨らみ部分７に対応した形状に発泡成形されて積層される。
こうして第２の上型１２を開いて成形品を取り出せばよく、これにより、硬度を異にする表層になる第１の発泡層１と、その裏面に接合された下層としての第２の発泡層２とからなる、図１に示す積層構造のクッションパッドＡ１を、従来と同様の成形工程で得ることができる。
このクッションパッドＡ１は、表層である第１の発泡層１のスリット形成部位の裏面側、すなわち第２の発泡層２との接合面側に膨らみ部分７が形成されているため、この第１の発泡層１の全体の厚みを大きくしなくても、前記の膨らみ部分７の厚みを利用して、スリット３の深さｂを深く設定することが可能になり、しかも溝底近傍に配置されている係止部材５が、スリット３の溝底３ａ及び接合面６に対して必要かつ充分な埋込み代ａ，ｃを確保することができる。
したがって、前記の第１の発泡層１の膨らみ部分７を有することにより、第１の発泡層１と第２の発泡層２の厚み配分、スリット３の深さｂを、それぞれ任意に設定でき、その設定の自由度を高めることができる。また、第１の発泡層１の全体的な厚みを薄く設定しながら、深溝のスリット３を付与することができる。
次に、本発明のクッションパッドの第２の実施例と、その製造装置について、図６〜図１０に基づいて説明する。
この第２の実施例においては、上記同様の積層構造をなすシート用クッションパッドＡ２において、第１の発泡層１の裏面側の膨らみ部分７の構成とは別に、パッド外周におけるパーティングライン部の凸感や硬さ感等の問題を解決する対策を講じた場合を示している。
すなわち、積層構造のクッションパッドの場合、例えば図１３のように、パッド外周には、表層である第１発泡層４１と裏層である第２発泡層４２との境界線４６が現れるとともに、成形型の下型と、第１の上型及び第２の上型との接合部によるパーティングラインＰＬ’が生じる。特に、従来のクッションパッドの場合、図１４に鎖線で示すように、成形型の下型６０と第１上型６１との接合部内端、および下型６０と第２上型６２との接合部内端が同じ位置にあって、パッド外周面における前記下型６０と第１の上型６１とによるパーティングラインと、前記下型６０と前記第２の上型６２とによるパーティングラインとが同じ位置になり、かつ前記境界線４６上に位置することになる。そのため、前記のパーティングラインＰＬ’の部分では、前記第１発泡層４１を成形した後、前記第２の発泡層４２を成形する際に、該第２発泡層用に配合した発泡樹脂原液が第１発泡層４１に含浸することによって、該第１発泡層４１の前記境界線４６に沿う部分が本来の硬さよりも硬くなり、これが、成形品であるクッションパッド外周において凸感及び硬さ感となって現れ、パッドに表皮材を被せた使用状態においても、前記凸感が生じたり、手触りによる異物感となったりして、質感を低下させるおそれがある。この第２の実施例で採用した構造は、前記のパーティングライン部の凸感や硬さ感等の問題を解決する。
なお、この第２の実施例において、第１の発泡層１のスリット形成部位の裏面側に膨らみ部分７を設ける点及びその関連構成、並びにその構成を得るための製造方法等については、上記した第１の実施例の場合と同様であるので、同構成の部位に同じ符号を付し、詳しい説明は省略する。
第２の実施例のクッションパッドＡ２の特徴的な構成について説明する。前記クッションパッドＡ２の外周には、成形型によるパーティングラインが形成されるが、図６及び図７に示すように、この第２の実施例のパッド外周におけるパーティングライン部ＰＬは、該ラインに沿って例えば前記第１の発泡層１の側が切欠されることにより溝状の凹部８が形成され、該第１の発泡層１とこれに積層される前記第２の発泡層２とのパッド外周に現れる境界線９が前記凹部８内の、特に内奥部に位置している。また、第１の発泡層１の成形時のパーティングラインＬ１は、後述するように前記境界線９と同じ位置に形成され、第２の発泡層２の成形時のパーティングラインＬ２は、前記凹部８の開口端側に形成されている。
前記のクッションパッドＡ２を得るための製造装置としての成形型は、図３に示す成形型と基本的に同様の構成をなしており、パッド表面側を成形する下型１０と、該下型に対し開閉可能な表層用の第１の上型１１と、裏層用の第２の上型１２とを備えてなる。
そして、図８〜図１０に示すように、前記下型１０には、その周側部における前記第１の上型１１および第２の上型１２との接合部１６の内周縁に、内方に向かって突出して周方向にリブ状に延びる凸部１５が設けられている。この凸部１５は、先端部が断面半円状の丸みを有する凸形状のほか、断面略台形状や断面略三角状をなす凸形状であってもよい。
前記の凸部１５の突出高さ及び幅は、それぞれ約３〜８ｍｍのものが好ましい。すなわち、前記凸部１５の突出高さや幅が前記寸法より小さくなると、該凸部１５により凹部８を形成することによる凸感や硬さ感等の防止効果が充分に得られないし、浮き上がり防止効果も少なくなる。また凸部１５の幅が小さくなりすぎると、凸部自体の強度が得られないおそれもある。また前記凸部１５の突出高さや幅が前記より大きくなると、凸部１５により形成される凹部８がかえって外観に凹凸感を生じさせることになり好ましくない。従って前記の効果の点から、凸部の突出高さや幅は５ｍｍ前後のものが最も好ましい。
また、前記の凸部１５は、前記接合部１６の全長に渡って形成する等、少なくともパッド両側部および前部に設けておくのが、外観的に目立ち易い部分のパーティングラインの質感向上等の点から好ましい。もちろん、両側部あるいは前後部のみに設けて実施することもできる。
一方、前記第１の上型１１は、前記下型１０に対し型閉じした状態において、図９のように、外周部における前記下型１０との接合部の内端側が前記凸部１５の上面に当接して、該下型１０と該第１の上型１１との接合部内端１８が前記凸部１５の先端部に位置するように設けられている。
また、前記第２の上型１２は、前記下型１０に対し型閉じした状態において、図１０のように、外周部における前記下型１０との接合部が前記凸部１５の上面に当接することなく、該下型１０と該第２の上型１２との接合部内端１９が前記凸部１５の基部に位置するように設けられている。
なお、前記下型１０の型内の所要の箇所に表皮材装着用のスリット３を形成するスリット形成片１３が突設されるほか、スリットワイヤ等の係止部材５の支持部（図示せず）等の、この種のクッションパッドの成形に必要な手段が設けられる。また、第１の上型１１には前記スリット形成部位の裏面側に膨らみ部分７を成形するための膨出部１７が形成される。
前記の成形型を備える製造装置によれば、従来装置の場合と同様に、下型１０と第１の上型１１により表層になる第１の発泡層１を、また下型１０と第２の上型１２とにより裏層になる第２の発泡層２を、それぞれ順次発泡成形して積層し一体化させることにより、前記の特徴を備えるクッションパッドＡ２を製造できる。その作用動作について説明する。
先ず、加熱調整された型を開いて、下型１０の上に、第１の発泡層１に適合するように配合した発泡樹脂原液、特にはウレタン原液を注入ヘッド２０により所要量注入する。そして前記第１の上型１１を図９のように閉じる。この型閉じ状態においては、該第１の上型１１の接合部の内端側が前記凸部１５の上に当接し、前記下型１０と第１の上型１１との接合部内端１８が前記凸部１５の先端部に位置することになる。そのため、この状態で第１の発泡層１を成形すると、図のように該第１の発泡層１の外周部上端に前記凸部１５による凹部８が形成され、前記接合部内端１８によるパーティングラインが該凹部８の内奥部に形成されることになる。なお、前記第１の発泡層１のスリット形成部位の裏面側には、第１の実施例の場合と同様に、膨出部１７によって膨らみ部分７が形成される。
この成形の後、成形された第１の発泡層１をそのままにして前記第１の上型１１を開くが、この際、前記第１の発泡層１の外周部が前記凸部１５に係合しているために、該第１の発泡層１が第１の上型１１に追従して浮き上がるのを防止でき、該第１の発泡層１を前記下型１０内に安定性よく保持しておくことができる。
そして、前記の型開き状態で、前記第１の発泡層１の上に、第２の発泡層に適合するように配合したウレタン原液等の樹脂原液を注入して、さらに前記第２の上型１２を閉じ、図１０のように第２の発泡層２を成形する。このとき、前記第２の上型１２は前記凸部１５の上面には当接せず、前記下型１０と前記第２の上型１２との接合部内端１９が該凸部１５の上面基部に位置している。従って、第１の発泡層１の上に成形され積層される第２の発泡層２は、図のように前記凸部１５の上面を覆う状態で成形されて、パッド外周に該凸部１５による溝状の凹部８が形成されるとともに、前記接合部内端１９によるパーティングラインが該凹部８の開口端に形成されることになる。
これにより、前記第１の発泡層１と第２の発泡層２が積層一体化されて図６に示す形態のクッションパッドＡ２が得られる。このクッションパッドＡ２の外周のパーティングライン部ＰＬにおいては、図７に拡大して示すように、第１の発泡層１の成形時の下型１０と第１上型１１との接合部内端１８によるパーティングラインＬ１と、第２発泡層２の成形時の下型１０と第２の上型１２との接合部内端１９によるパーティングラインＬ２とが、前記凹部８の内奥部と開口端とに形成される。また前記接合部内端１８によるパーティングラインＬ１と一致する前記第１の発泡層１と第２の発泡層２との境界線９が、前記凹部８の内奥部に位置し、パッド外周面には現れない。
このため、前記クッションパッドＡ２は、仮に第２の発泡層２の樹脂原液が第１の発泡層１に含浸することがあっても、パッド外周面において従来のパーティングラインのような凸感や硬さ感は生じず、当該クッションパッドＡ２に表皮材を被せた使用状態での質感を良好に確保できるものとなる。
特に、前記凸部１５が少なくともパッド両側部および前部に設けられていると、これにより得られるクッションパッドＡ２は、その使用状態において外観的に目立ち易い部分のパーティングライン部ＰＬにおいて、凸感や手触りに異物感を生じさせないものとなる。
なお、上記した実施例においては、凸部１５による凹部８を、第１の発泡層１の側に形成した場合を示したが、このほか、前記凸部１５により、第１の発泡層１と第２の発泡層２の両者にわたる凹部を形成して実施することもできる。
また、前記の第２の実施例のパーティングライン部ＰＬの構造、すなわち、パーティングラインの凸感および硬さ感等を解消するために、該ラインに沿って溝状の凹部８を設けて、第１の発泡層１の成形時のパーティングラインＬ１と、第２の発泡層２の成形時のパーティングラインＬ２とを前記凹部８の内奥部と開口端とに形成する点は、前記第１の発泡層１のスリット形成部位の裏面側に膨らみ部分を有さない形態のクッションパッドにも適用できる。
この第２の実施例のクッションパッド及びその製造装置については、その特徴を次のようにまとめることができる。
（ａ） 硬度の異なる２種の樹脂発泡層を表裏層とする積層構造のシート用クッションパッドであって、パッド外周におけるパーティングライン部は、該ラインに沿って少なくとも表層としての第１の発泡層の側に溝状の凹部が形成されており、該第１の発泡層とこれに積層される第２の発泡層との境界線が該凹部内に位置しているもの。
（ｂ） 硬度の異なる２種の樹脂発泡層を表裏層とする積層構造のシート用クッションパッドの製造装置であって、パッド表面を成形する下型と、該下型に対しそれぞれ開閉自在な表層用の第１の上型及び裏層用の第２の上型とを備える成形型よりなり、表層としての第１の発泡層と、裏層としての第２の発泡層とを順次発泡成形して積層するようにした製造装置において、前記下型には、前記第１の上型および第２の上型との接合部の内周縁に、内方に向かって突出する凸部が設けられ、該下型と該第１の上型との接合部内端が前記凸部の先端側に、該下型と該第２の上型との接合部内端が前記凸部の上面基部側に位置するように設けられてなるもの。
（ｃ） 前記シート用クッションパッドの製造装置において、前記凸部が少なくともパッド両側部および前部に設けられてなるもの。
（ｄ） 前記シート用クッションパッドの製造装置において、前記凸部の突出高さ及び幅がそれぞれ約３〜８ｍｍであるもの。Next, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.
FIG. 1 is a sectional view showing a first embodiment of a cushion pad according to the present invention, and FIG. 2 is an enlarged sectional view of a part of the cushion pad.
The cushion pad A1 for seats according to the present invention is composed of two foamed resin foam layers such as urethane foams having different hardnesses, and as shown in the figure, the first foam as a surface layer on the contact side with the user. A layer 1 and a second foam layer 2 as a back layer (lower layer) which is higher in density and slightly harder than the first foam layer 1 and is bonded to the back surface of the first foam layer 1 are laminated. It becomes. In the figure, reference numeral 1a denotes a central part serving as a seat part on the pad surface, and 1b and 1b denote both side parts raised slightly higher than the central part 1a.
In the first foam layer 1 as the surface layer, a slit 3 for attaching a skin material is formed between required portions on the pad surface side, for example, between the central portion 1a and both side portions 1b, 1b, A rod-like locking member 5 called a slit wire is embedded in the vicinity of the groove bottom of the slit 3 to lock locking means provided at the end of a skin material (not shown) such as fabric or leather. Thus, it can be mounted in a state of being sandwiched between the slits.
The first foam layer 1 is formed such that the joint surface 6 with the second foam layer 2 forms a bulge shape toward the second foam layer 2 on the back surface side of the slit forming portion. That is, the joint surface 6 is formed to have a curved convex shape that is recessed toward the second foamed layer 2 side from the joint surface position 6a (shown by an imaginary line) of the conventional shape on the back surface side of the slit forming portion. Has been. Even when the depth b of the slit 3 is formed close to the joint surface position 6a of the conventional shape or deeper than the position by the convex bulging portion 7, the groove bottom of the slit 3 is also formed. The locking member 5 embedded in this portion is formed so as to be able to have an embedding allowance greater than or equal to a predetermined distance between 3 a and the joint surface 6.
The height of the bulging portion 7 should be set so that an embedding allowance c of the engaging member 5 with respect to the joint surface 6 is at least 10 mm, and an embedding allowance a with respect to the groove bottom 3a is at least 5 mm. Well, this can surely prevent the locking member 5 from coming off.
The shape of the bulging portion 7 of the joint surface 6 of the first foam layer 1 is preferably a curve as shown in the figure, but it has an angular bulge shape such as a substantially trapezoidal cross section. May be.
In any case, the second foam layer 2 laminated on the back surface of the first foam layer 1 has a recessed shape corresponding to the shape of the bulging portion 7 and the back surface of the first foam layer 1. Are joined together and laminated together.
A method for manufacturing the cushion pad A1 will be described below together with an apparatus used for manufacturing the cushion pad A1.
FIG. 3 schematically shows a molding die for molding the cushion pad A1 having the above-described laminated structure. FIGS. 4 and 5 are foam moldings of the first foam layer and the second foam layer by the same mold, respectively. Indicates the state.
The forming die is formed with the front and back sides of the cushion pad A1 reversed, and has a lower die 10 having a concave shape and two upper dies that can be opened and closed with respect to the lower die, that is, a first for the surface layer. An upper mold 11 and a second upper mold 12 for the back layer are provided. Each mold is formed of a metal material such as aluminum.
The lower mold 10 molds the pad surface, and a slit forming piece 13 for forming a slit 3 for attaching the skin material protrudes in the mold and is embedded in the foam. A fixing support portion (not shown) for fixing and supporting the locking member 5 in a detachable manner is provided. For example, when the slit 3 and the locking member 5 are provided between the central portion 1a serving as the seat portion and the both side portions 1b and 1b as shown in FIG. 1, the slit forming piece is provided at a position in the mold corresponding to the position. And a fixed support.
The first upper mold 11 and the second upper mold 12 are hinged to the lower mold 10, respectively, so that the mold can be alternately closed and opened. The first foamed layer 1 as a surface layer is molded in a state where the mold is closed, and the second foamed layer 2 is molded in a state where the second upper mold 12 is closed. It can be laminated and integrated by molding. Reference numerals 14a and 14b in the figure respectively denote hinge coupling portions. Since the mechanism for opening and closing the upper molds 11 and 12 can be the same as the conventional mechanism, the illustration and explanation thereof will be omitted.
The first upper mold 11 of the molding die used in the present invention is disposed in the lower mold 10 in a state in which the portion corresponding to the back side of the slit forming portion is closed with respect to the lower mold 10. The slit forming piece 13 and the locking member 5 are formed so as to bulge upward in a curved convex shape so as to bypass the slit forming piece 13 and the locking member 5. Reference numeral 17 denotes a bulge portion of the first upper mold 11 and corresponds to the shape of the bulge portion 7 of the first foam layer 1 described above.
When the cushion pad is formed by the above-described mold, it is formed by the same procedure as before. First, a foamed resin stock solution formulated to fit the first foamed layer on the lower mold 10 in a state where the heated and adjusted mold is opened and the locking member 5 such as a wire is fixedly supported, in particular, A required amount of urethane stock solution is injected by the injection head 20. Then, the first upper mold 11 is closed, foam molding is performed as shown in FIG. 4, and the first foam layer 1 is molded with the slit forming piece 13 and the locking member 5 embedded in the foam. To do. Further, since the portion corresponding to the back surface side of the slit forming portion of the first upper mold 11 has a shape bulging upward, the back surface side of the slit forming portion of the first foam layer 1 is formed. A bulging portion 7 is formed, and the locking member 5 is embedded in the bulging portion 7. The height and shape of the bulging portion 7 are determined by the bulging portion 17 of the first upper mold 11. Therefore, by appropriately setting the height of the bulging portion 17, the bulging portion 7 having an arbitrary height and shape can be formed.
Thereafter, the first upper mold 11 is opened, and a required amount of a foamed resin stock solution, for example, a urethane stock solution, formulated so as to be compatible with the second foamed layer is injected onto the first foamed layer 1. The second upper mold 12 is closed, and the second foam layer 2 is foam-molded as shown in FIG. 5 and joined and integrated with the first foam layer 1. That is, the second foam layer 2 is foam-molded into a shape corresponding to the bulging portion 7 on the back surface side of the first foam layer 1 and laminated.
Thus, the second upper mold 12 may be opened to take out the molded product, whereby the first foamed layer 1 serving as the surface layer having different hardness and the second foamed layer as the lower layer joined to the back surface thereof. A cushion pad A1 having a laminated structure shown in FIG.
Since this cushion pad A1 has a bulging portion 7 formed on the back surface side of the slit forming portion of the first foam layer 1 which is the surface layer, that is, the joint surface side with the second foam layer 2, the first pad 1 Without increasing the overall thickness of the foam layer 1, the depth b of the slit 3 can be set deep using the thickness of the bulging portion 7 and is disposed near the bottom of the groove. The locking member 5 that is provided can secure the necessary and sufficient embedding margins a and c for the groove bottom 3 a and the joint surface 6 of the slit 3.
Therefore, by having the bulging portion 7 of the first foam layer 1, the thickness distribution of the first foam layer 1 and the second foam layer 2 and the depth b of the slit 3 can be arbitrarily set, The degree of freedom of the setting can be increased. Moreover, the deep groove slit 3 can be provided while setting the overall thickness of the first foam layer 1 to be thin.
Next, a second embodiment of the cushion pad of the present invention and its manufacturing apparatus will be described with reference to FIGS.
In the second embodiment, in the seat cushion pad A2 having the same laminated structure as described above, apart from the configuration of the bulging portion 7 on the back surface side of the first foam layer 1, the parting line portion on the outer periphery of the pad is provided. This shows a case where measures are taken to solve problems such as convexity and hardness.
That is, in the case of a cushion pad having a laminated structure, for example, as shown in FIG. 13, a boundary line 46 between the first foam layer 41 as the surface layer and the second foam layer 42 as the back layer appears on the outer periphery of the pad, and molding is performed. A parting line PL ′ is formed by a joint between the lower mold of the mold and the first upper mold and the second upper mold. In particular, in the case of a conventional cushion pad, as shown by a chain line in FIG. 14, the inner end of the joint between the lower mold 60 and the first upper mold 61 and the joint between the lower mold 60 and the second upper mold 62 are shown. The part is located at the same position, and the parting line formed by the lower mold 60 and the first upper mold 61 on the pad outer peripheral surface is the same as the parting line formed by the lower mold 60 and the second upper mold 62. And is located on the boundary line 46. Therefore, in the part of the parting line PL ′, when the second foamed layer 42 is formed after the first foamed layer 41 is molded, the foamed resin stock solution blended for the second foamed layer is By impregnating the first foamed layer 41, the portion along the boundary line 46 of the first foamed layer 41 becomes harder than the original hardness, and this is a sense of convexity and hardness on the outer periphery of the cushion pad that is a molded product. Even when the pad is covered with a skin material, the above-mentioned convexity may be generated or a foreign object may be felt due to the touch, which may reduce the texture. The structure adopted in the second embodiment solves the problems such as the convexity and hardness of the parting line portion.
In addition, in this 2nd Example, about the point which provides the bulging part 7 in the back surface side of the slit formation site | part of the 1st foaming layer 1, its related structure, the manufacturing method for obtaining the structure, etc. were mentioned above. Since it is the same as in the case of the first embodiment, the same reference numerals are given to the parts having the same configuration, and detailed description will be omitted.
A characteristic configuration of the cushion pad A2 of the second embodiment will be described. A parting line by a molding die is formed on the outer periphery of the cushion pad A2. As shown in FIGS. 6 and 7, the parting line portion PL on the outer periphery of the pad of the second embodiment is the line. For example, a groove-shaped recess 8 is formed by cutting out the first foam layer 1 side along the surface, and a pad between the first foam layer 1 and the second foam layer 2 laminated thereon is formed. A boundary line 9 appearing on the outer periphery is located in the recess 8, particularly at the inner back. Further, the parting line L1 at the time of molding the first foam layer 1 is formed at the same position as the boundary line 9 as described later, and the parting line L2 at the time of molding the second foam layer 2 is It is formed on the opening end side of the recess 8.
The molding die as a manufacturing apparatus for obtaining the cushion pad A2 has basically the same configuration as the molding die shown in FIG. 3, and includes a lower die 10 for molding the pad surface side, and the lower die. A first upper mold 11 for the surface layer that can be opened and closed and a second upper mold 12 for the back layer are provided.
Then, as shown in FIGS. 8 to 10, the lower mold 10 has an inner edge on the inner peripheral edge of the joint portion 16 with the first upper mold 11 and the second upper mold 12 on the circumferential side portion. A convex portion 15 is provided that protrudes toward the surface and extends in a rib shape in the circumferential direction. The convex portion 15 may have a convex shape having a substantially trapezoidal cross section or a substantially triangular cross section, in addition to a convex shape having a semicircular cross section at the tip.
The protrusion height and width of the protrusion 15 are preferably about 3 to 8 mm. That is, when the protruding height and width of the convex portion 15 are smaller than the above dimensions, the convexity and hardness preventive effect due to the concave portion 8 being formed by the convex portion 15 is not sufficiently obtained, and the floating prevention effect is not obtained. Less. If the width of the convex portion 15 is too small, the strength of the convex portion itself may not be obtained. Further, if the protruding height or width of the convex portion 15 is larger than the above, it is not preferable because the concave portion 8 formed by the convex portion 15 changes to give a sense of unevenness to the appearance. Therefore, in terms of the above effects, the protrusion height and width of the protrusion are most preferably around 5 mm.
In addition, the convex portion 15 is formed over the entire length of the joint portion 16, and is provided at least on both sides and the front portion of the pad. From the point of view, it is preferable. Of course, it can also be carried out by providing only on both sides or front and rear.
On the other hand, when the first upper mold 11 is closed with respect to the lower mold 10, the inner end side of the joint portion with the lower mold 10 in the outer peripheral portion is the upper surface of the convex portion 15 as shown in FIG. 9. The joint inner end 18 of the lower mold 10 and the first upper mold 11 is provided so as to be positioned at the tip of the convex portion 15.
Further, when the second upper mold 12 is closed with respect to the lower mold 10, the joint portion with the lower mold 10 in the outer peripheral portion abuts on the upper surface of the convex portion 15 as shown in FIG. 10. Instead, the inner end 19 of the joint between the lower mold 10 and the second upper mold 12 is provided at the base of the convex portion 15.
In addition, a slit forming piece 13 for forming the slit 3 for attaching the skin material protrudes at a required location in the mold of the lower mold 10, and a support portion (not shown) of the locking member 5 such as a slit wire. The means necessary for molding this type of cushion pad is provided. Further, the first upper mold 11 is formed with a bulging portion 17 for forming the bulging portion 7 on the back surface side of the slit forming portion.
According to the manufacturing apparatus including the above-described mold, as in the case of the conventional apparatus, the first foam layer 1 that becomes the surface layer by the lower mold 10 and the first upper mold 11, and the lower mold 10 and the second mold Cushion pad A2 provided with the said characteristic can be manufactured by carrying out the foaming molding of the 2nd foaming layer 2 used as a back layer with the upper mold | type 12, respectively, laminating | stacking and integrating. The operation will be described.
First, the mold that has been heat-adjusted is opened, and a required amount of a foamed resin stock solution, particularly a urethane stock solution, blended so as to be compatible with the first foamed layer 1 is injected onto the lower mold 10 by the injection head 20. Then, the first upper mold 11 is closed as shown in FIG. In this mold closed state, the inner end side of the joint portion of the first upper mold 11 abuts on the convex portion 15, and the joint inner end 18 of the lower mold 10 and the first upper mold 11 is It will be located at the tip of the convex portion 15. Therefore, when the first foam layer 1 is molded in this state, the concave portion 8 is formed by the convex portion 15 at the upper end of the outer peripheral portion of the first foam layer 1 as shown in the figure, and the parting by the joint inner end 18 is performed. A line is formed at the inner back of the recess 8. Note that a bulging portion 7 is formed by a bulging portion 17 on the back side of the slit forming portion of the first foam layer 1 as in the case of the first embodiment.
After the molding, the first upper mold 11 is opened with the molded first foam layer 1 as it is. At this time, the outer peripheral portion of the first foam layer 1 is engaged with the convex portion 15. Therefore, the first foam layer 1 can be prevented from floating following the first upper mold 11, and the first foam layer 1 can be stably held in the lower mold 10. I can leave.
And in the said mold open state, resin stock solutions, such as a urethane stock solution mix | blended so that it might match a 2nd foam layer, were inject | poured on the said 1st foam layer 1, and also said 2nd upper mold | type. 12 is closed and the second foamed layer 2 is formed as shown in FIG. At this time, the second upper mold 12 does not contact the upper surface of the convex portion 15, and the joint inner end 19 of the lower mold 10 and the second upper mold 12 is the upper surface base of the convex portion 15. Is located. Accordingly, the second foamed layer 2 molded and laminated on the first foamed layer 1 is molded so as to cover the upper surface of the convex portion 15 as shown in the figure, and is formed on the outer periphery of the pad by the convex portion 15. A groove-like recess 8 is formed, and a parting line by the joint inner end 19 is formed at the opening end of the recess 8.
Thereby, the first foamed layer 1 and the second foamed layer 2 are laminated and integrated to obtain a cushion pad A2 having the form shown in FIG. In the parting line portion PL on the outer periphery of the cushion pad A2, as shown in an enlarged view in FIG. 7, the joint inner end 18 of the lower mold 10 and the first upper mold 11 when the first foam layer 1 is molded. And the parting line L2 formed by the joint inner end 19 of the lower mold 10 and the second upper mold 12 when the second foamed layer 2 is molded are the inner part of the recess 8 and the open end. And formed. Further, a boundary line 9 between the first foamed layer 1 and the second foamed layer 2 that coincides with the parting line L1 formed by the joint inner end 18 is located in the inner back part of the recess 8 and is formed on the pad outer peripheral surface. Does not appear.
For this reason, even if the cushion pad A2 may impregnate the first foamed layer 1 with the resin stock solution of the second foamed layer 2, the pad outer peripheral surface may have a convex feeling like a conventional parting line. A feeling of hardness does not occur, and it is possible to satisfactorily ensure the texture in the use state where the cushion pad A2 is covered with the skin material.
In particular, when the convex portion 15 is provided at least on both sides and the front portion of the pad, the cushion pad A2 obtained thereby has a convex sensation in the parting line portion PL which is visually noticeable in its use state. And the touch will not cause a foreign body sensation.
In addition, in the above-mentioned Example, although the case where the recessed part 8 by the convex part 15 was formed in the 1st foam layer 1 side was shown, in addition to this, with the 1st foam layer 1 by the said convex part 15, It is also possible to carry out by forming a recess extending over both of the second foam layer 2.
Further, in order to eliminate the structure of the parting line portion PL of the second embodiment, that is, the feeling of convexity and hardness of the parting line, a groove-like recess 8 is provided along the line. The point of forming the parting line L1 at the time of molding the first foam layer 1 and the parting line L2 at the time of molding the second foam layer 2 at the inner back portion and the open end of the recess 8 is as follows. The present invention can also be applied to a cushion pad that does not have a bulging portion on the back surface side of the slit forming portion of the first foam layer 1.
About the cushion pad of this 2nd Example and its manufacturing apparatus, the characteristic can be put together as follows.
(A) A cushion pad for a sheet having a laminated structure in which two types of resin foam layers having different hardnesses are used as front and back layers, and a parting line portion on the outer periphery of the pad is at least a first foam as a surface layer along the line A groove-like recess is formed on the side of the layer, and a boundary line between the first foam layer and the second foam layer laminated thereon is located in the recess.
(B) An apparatus for manufacturing a cushion pad for a sheet having a laminated structure in which two types of resin foam layers having different hardnesses are used as front and back layers, a lower mold for forming the pad surface, and a surface layer that can be opened and closed with respect to the lower mold. A first upper mold for the back and a second upper mold for the back layer, and the first foam layer as the surface layer and the second foam layer as the back layer are sequentially foam-molded. The lower mold is provided with a convex portion projecting inwardly on the inner peripheral edge of the joint portion between the first upper mold and the second upper mold, The joint inner end of the lower mold and the first upper mold is located on the tip side of the convex part, and the joint inner end of the lower mold and the second upper mold is located on the upper surface base side of the convex part. What is provided.
(C) In the seat cushion pad manufacturing apparatus, the convex portions are provided at least on both sides and the front of the pad.
(D) In the manufacturing apparatus of the cushion pad for seats, the protruding height and width of the convex portion are each about 3 to 8 mm.

産業上の利用の可能性Industrial applicability

本発明は、硬度の異なる２種の樹脂発泡層を積層した積層構造のクッションパッドとして、発泡層の厚み配分と表皮材装着用スリットの深さの設定の自由度が高く、深溝スリットにして、しかもスリットワイヤ等の係止部材の埋込み代を充分に確保できるものを提供できるので、自動車等のシート用クッションパッドに好適に利用できる。  As a cushion pad of a laminated structure in which two types of resin foam layers having different hardnesses are laminated, the present invention has a high degree of freedom in setting the thickness distribution of the foam layer and the depth of the slit for attaching the skin material. In addition, since it is possible to provide a member that can sufficiently secure an embedding allowance of a locking member such as a slit wire, it can be suitably used for a cushion pad for a seat such as an automobile.

Claims (3)

硬度の異なる２種の樹脂発泡層を積層した積層構造をなし、表層としての第１の発泡層に、表皮材装着用のスリットが形成され、該スリットの溝底近傍に棒状の係止部材が埋設されてなるクッションパッドであって、
前記第１の発泡層は、前記スリット形成部位における裏面側が、その裏面に接合される第２の発泡層側への膨らみ形状をなすように成形されており、この膨らみ部分により前記係止部材が所定以上の埋込み代を保有して埋設されていることを特徴とするシート用クッションパッド。A laminated structure in which two types of resin foam layers having different hardnesses are laminated, a slit for attaching a skin material is formed in the first foam layer as the surface layer, and a rod-shaped locking member is provided near the groove bottom of the slit. An embedded cushion pad,
The first foam layer is formed such that the back surface side of the slit forming portion forms a bulge shape toward the second foam layer side to be joined to the back surface. A cushion pad for a seat, which is embedded with an embedding allowance greater than a predetermined value. 前記係止部材が、前記第２の発泡層との接合面との間には少なくとも１０ｍｍの埋込み代、スリットの溝底との間には少なくとも５ｍｍの埋込み代を、それぞれ保有して埋設されている請求項１に記載のシート用クッションパッド。The locking member is embedded with an embedding allowance of at least 10 mm between the joint surface with the second foam layer and an embedding allowance of at least 5 mm between the groove bottom of the slit. The cushion pad for seats according to claim 1. パッド表面を成形する下型と、該下型に対しそれぞれ開閉自在な表層用の第１の上型及び下層用の第２の上型を備えてなる成形型を用い、表層としての第１の発泡層と、その裏面に接合される下層としての第２の発泡層とを順次発泡成形して積層するとともに、前記第１の発泡層に、表皮材装着用のスリットを形成し、該スリットの溝底近傍に棒状の係止部材を埋設する、クッションパッドの製造方法において、
前記第１の上型の前記スリット形成部位の裏面側に相当する部分を、型閉じ状態において下型内に配置されるスリット形成片及び係止部材を迂回する上方への膨出形状をなすように形成しておき、前記下型に第１の発泡樹脂原液を注入し前記第１の上型を閉じて前記第１の発泡層を発泡成形する際、前記第１の上型により、第１の発泡層の前記スリット形成部位の裏面側を上方に膨らみを持たせるように成形することを特徴とするシート用クッションパッドの製造方法。Using a molding die comprising a lower die for molding the pad surface, a first upper die for the surface layer that can be opened and closed with respect to the lower die, and a second upper die for the lower layer, the first as the surface layer The foam layer and a second foam layer as a lower layer bonded to the back surface thereof are sequentially foam-molded and laminated, and a slit for attaching a skin material is formed in the first foam layer. In the method of manufacturing a cushion pad in which a rod-shaped locking member is embedded in the vicinity of the groove bottom,
A portion corresponding to the back surface side of the slit forming portion of the first upper mold has an upward bulging shape that bypasses the slit forming piece and the locking member disposed in the lower mold when the mold is closed. When the first foamed resin stock solution is injected into the lower mold and the first upper mold is closed to foam the first foam layer, the first upper mold is used to A method for producing a cushion pad for a seat, comprising molding the back surface side of the slit forming portion of the foamed layer so as to bulge upward.
JP2004544723A 2002-10-18 2003-02-05 Cushion pad for seat and manufacturing method thereof Expired - Fee Related JP4134039B2 (en)

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