JP5394214B2 - Seat back pad and manufacturing method thereof - Google Patents

Description

  The present invention relates to a seat back pad used in an automobile or the like and a method for manufacturing the same.

  In general, a back pad used as a cushioning material in a backrest portion of a vehicle seat is made of a molded product of foamed resin such as flexible polyurethane foam, and is assembled to a metal frame and covered with a skin material. And it is comprised as a backrest part of the vehicle seat. In order to hold the frame, the seat back pad is integrally provided with an inward projecting portion on the upper side portion on the back side of the pad main body (see, for example, Patent Documents 1 and 2 below).

  When a backboard such as a resin panel is provided on the back of the backrest to give a high-quality appearance to the backrest or to add functions such as a table sheet to the back of the backrest (See Patent Document 3 below).

  FIG. 8 shows an example in which a backboard 2 is provided on the back of a backrest 1 in a front seat of an automobile, and a skin material 3 is covered on the back pad.

JP 2009-072916 A JP 2008-183129 A JP 2007-082909 A

  In the back pad of the back board specification as described above, as shown in FIG. 9, the front end portion of the flange portion 102 in the protruding portion 101 of the back pad 100 is thin so as to receive the upper edge portion 2A of the back board 2. The flange portion 102 is formed of a thick portion 103 and a thin portion 104. When the back pad 100 having such a flange portion 102 is subjected to foam molding using a foam molding die, the parting line PL of the molding die is lower than the top of the thick portion 103, so that the outer surface of the thick portion 103 is formed. Air accumulation is likely to occur, and defects caused thereby cause poor appearance.

  As measures to make it difficult for air accumulation to occur, the step G between the thick portion 103 and the thin portion 104 is reduced, or the radius of curvature of the corner portion 105 from the thick portion 103 to the thin portion 104 is increased. It can be considered that the corner portion 105 is smoothed. However, these measures impair the high-quality appearance.

  Therefore, for example, as shown in FIG. 10 (a), a measure of providing the slit groove 106 for releasing the foaming gas from the apex of the thick portion 103 toward the parting line PL is conceivable. Air accumulation may occur, and the effect is small. Further, as shown in FIG. 10B, a measure of embedding and integrating the slab urethane 107 in the thick portion 103 is also conceivable. However, in the case of the slab urethane 107, there is a problem that the terminal is hardened to give a foreign object feeling, or if the gas escape is bad, the slab urethane 107 is depressed and does not make sense.

  The present invention has been made in view of the above points, and in the back pad for seats of the back board specification, it is difficult to cause molding defects and improves the appearance of the back portion of the seat, particularly the appearance around the back board. With the goal.

  The seat back pad according to the present invention constitutes a backrest portion of a vehicle seat having a backboard on the back surface, and an overhang portion is integrally provided on the upper side portion on the back side of the pad body made of flexible foam. The overhanging portion includes a connecting portion extending rearward from the pad main body, and a flange portion extending downward from the connecting portion with a gap from the back surface of the pad main body. The flange portion is formed in a thick portion on the connecting portion side, and the front end side falls to the front so as to receive the upper edge portion of the backboard. It is formed in the thin part which makes. A molded sheet body is provided on the outer surface of the flange portion, and the molded sheet body includes a first surface portion having a shape along the outer surface of the thick portion and a second surface portion having a shape along the outer surface of the stepped portion. It is three-dimensionally molded in advance with a bent cross section, and is integrated with the outer surface of the flange portion by foam molding of the flexible foam.

  The manufacturing method of the seat back pad according to the present invention includes a lower mold that molds the front side of the pad main body, an upper mold that molds the outer surface of the flange portion, and the pad when the seat back pad is manufactured. Using a foam molding die provided with a back surface of the main body and a core die for molding the inner surface of the connecting portion and the flange portion, the three-dimensionally molded sheet body is set in the upper die, and the lower die A foamed resin stock solution is injected into the lower mold, and the upper mold and the core mold are closed with respect to the lower mold to perform foam molding.

  According to the present invention, by using a molded sheet body that has been pre-formed into a shape along the outer surface of the flange portion, and by integrating this with the outer surface of the flange portion by foam molding of a flexible foam, Defects can be prevented, molding defects can be suppressed, and the finished appearance of the sheet can be improved.

  In addition, as described in Patent Document 2, it has been known that a three-dimensionally formed sheet body is integrated by foam molding of the pad main body. However, in the related art, a non-design such as the back of the pad main body is known. Is integrated with the surface (that is, the portion that does not appear outside when the sheet is assembled), and the molded sheet body is integrated with the design surface that appears outside through the skin material, as in the present invention. It has not been known to improve the appearance of the part.

The perspective view of the back side of the back pad for sheets concerning one embodiment of the present invention II-II sectional view of FIG. Upper enlarged back view of back pad for seat Sectional view taken along line IV-IV in FIG. Cross-sectional view of a foam molding die for molding the back pad for the sheet Expanded sectional view of the main part of the foam mold Plan view of molded felt used for back pad for the same sheet Perspective view of seat backrest with backboard Sectional drawing equivalent to the IX-IX line of FIG. (A) is an enlarged cross-sectional view of the main part of the back pad when a slit groove is provided as a countermeasure against air accumulation, and (b) is an enlarged cross-sectional view of the main part when slab urethane is embedded and integrated.

  Embodiments of the present invention will be described below with reference to the drawings.

  The back pad 10 of the embodiment shown in FIGS. 1 and 2 is a pad used as a cushion material in a backrest portion of a front seat of an automobile, for example. The back pad 10 includes a pad main body 12 made of a flexible foam such as a flexible polyurethane foam, and a reinforcing cloth 14 laminated and integrated on the back side thereof, and woven or knitted fabric or leather is sewn together. The surface is covered with the skin material 3 (see FIG. 8), assembled to the frame 4 (see FIG. 4), and the backboard 2 made of resin (see FIG. 8) is attached to the back side, thereby forming a backrest portion. To do.

  An inward flange-like overhanging portion 16 for mounting the frame 4 is integrally provided on the upper side portion 12 </ b> A on the back side of the pad main body 12 over the entire width of the pad main body 12. The overhanging portion 16 extends from the pad main body 12 so as to protrude rearward Z1, and to the lower X1 that is inward from the connecting portion 18 so as to have a predetermined distance L from the back surface of the pad main body 12. An extended flange portion 20 is provided, and is formed in a bag shape that opens downward together with the pad main body 12.

  As shown in an enlarged view in FIG. 4, the flange portion 20 has a connecting portion 18 side (that is, an upper side) formed in a thick portion 22 and a tip end side (that is, a lower end portion) via a step portion 24. The thin portion 26 is formed. Specifically, the flange portion 20 is formed in a concave shape in which the outer surface of the lower end portion falls into the front Z2 so as to receive the upper end portion 2A of the backboard 2 at the lower end portion thereof. Is formed in a thin shape through a step portion 24 with respect to the thick portion 22 on the upper side. Accordingly, the outer surface 20A (that is, the rear surface) of the flange portion 20 includes an outer surface 22A of the thick portion 22 protruding to the rear Z1 on the upper side of the flange portion 20 and a thin portion recessed to the front Z2 on the lower side of the flange portion 20. 26, and an outer surface 24A of the step portion 24 extending in the horizontal direction (that is, the front-rear direction) so as to connect the two.

  The thick wall portion 22 has a protruding amount toward the rear Z1 so that the back board 2 is assembled so as to cover the thin wall portion 26, and the back wall 2 is equivalent to or protrudes from the rear Z1. It is set, and this enhances the design effect.

  As shown in FIGS. 3 and 4, a molded sheet body 28 is provided on the outer surface 20 </ b> A of the flange portion 20. The molded sheet body 28 includes a first surface portion 30 having a shape along the outer surface 22A of the thick portion 22 and a second surface portion 32 having a shape along the outer surface 24A of the stepped portion 24. It is integrated with the outer surface 20A of the flange portion 20 by foam molding of the flexible polyurethane foam. In this embodiment, the molded sheet body 28 further includes a third surface portion 34 having a shape along the outer surface 26 </ b> A of the thin portion 26, and in the region from the thick portion 22 to the thin portion 26 through the step portion 24. The three-dimensional shape is formed in advance along the shape of the outer surface 20A.

  The first surface portion 30 is formed in the vertical direction X along the outer surface 22A of the thick portion 22, and the design surface on the back side of the back pad 10 (peripheral portion along the upper edge portion 2A of the backboard 2). Form. In this example, the first surface portion 30 is formed over substantially the entire vertical direction X of the thick portion 22. The second surface portion 32 is formed in a bent shape from the lower end of the first surface portion 30 to the front Z2, and is provided so as to cover the entire outer surface 24A of the stepped portion 24. The corner portion 36 connecting the first surface portion 30 and the second surface portion 32 is formed in a circular arc shape as shown in FIG. 4 and enhances the design effect on the appearance. The third surface portion 34 is formed to be bent downward X1 from the front end of the second surface portion 32 and can be provided over the whole of the thin portion 26 in the vertical direction X. In this example, the upper end portion of the thin portion 26 is provided. It is provided so as to cover only.

  As shown in FIGS. 3 and 7, the molded sheet body 28 has both ends in the width direction Y of the back pad 10 having a planar arch shape in which the vertical dimension is gradually smaller toward the tip and curved downward X1. The flange portion 20 is provided over the entire width direction Y.

  A concave groove 37 is formed in the molded sheet body 28 to accommodate the stitched portion 3A (see FIG. 8) of the skin material 3 and enhance the design effect of the back pad 10 in the back view. The concave groove 37 is a groove formed by being recessed in the thickness direction so that the molded sheet body 28 protrudes to the back surface side. In this example, the concave and convex portions 37 are vertically moved in the first surface portion 30 corresponding to the outer surface 22A of the thick portion 22. It extends in the direction X and is provided at two locations in the width direction Y of the flange portion 20. Thus, since the concave groove 37 is provided in the molding sheet body 28, it is not necessary to provide a protruding line for molding such a concave groove 37 in the foaming mold.

  As shown in FIG. 7, a magnetic member 38 that can be magnetically attracted to a permanent magnet 62 provided in the foaming mold 50 is attached to the molded sheet body 28. Examples of the magnetic member 38 include an adhesive sheet piece containing metal powder and a small metal piece such as a staple of a stapler. Here, an adhesive sheet piece containing iron powder is used. The magnetic body member 38 is provided with a through hole 40 in the first surface portion 30 that serves as a design surface, in order to increase the magnetic attractive force at the time of molding without impairing the appearance in the product state. (That is, it is affixed to the surface of the flexible foam side). On the other hand, the magnetic body member 38A at both end portions of the third surface portion 34 serving as a non-design surface is directly attached to the outer surface.

The molded sheet body 28 as described above is not particularly limited as long as it has rigidity capable of retaining the above-mentioned three-dimensionally molded shape. For example, a plastic molded body may be used, but preferably, a molded felt body is used. Such a fiber member. If it is a fiber member, since it has air permeability, the degassing effect from the molded sheet body 28 can also be expected. Examples of the forming felt include various compression felts obtained by thermoforming. Specifically, fibers such as cotton, rayon, nylon, and polyester are arranged in a web or mat shape by an appropriate method. Can be pressed with various binders to bond the fibers together, or hot pressed without using a binder and the fibers themselves can be bonded to each other by fusing. Can be easily three-dimensionally formed into the above shape. Although not particularly limited, a molded felt having a basis weight of about 100 to 400 g / m ² and a thickness of about 1 to 5 mm is preferably used.

  The reinforcing cloth 14 is sewn in a bag shape, and is integrated by foam molding of the flexible polyurethane foam so as to cover the back surface of the pad main body 12 and the inner surface of the overhanging portion 16. The reinforcing cloth 14 can be used without particular limitation as long as it has appropriate air permeability and can prevent the polyurethane foam from oozing out during foam molding, and can be used without any limitation. A complex or the like can be used. As the reinforcing cloth 14, a material that is more flexible than the molded sheet body 28 is used.

  As shown in FIG. 5, the foam mold 50 for molding the back pad 10 is formed with a lower mold 52 that is recessed so as to mold the front side of the pad body 12 and an outer surface 20 </ b> A of the flange portion 20. An upper die 54, and a core die 56 for molding the back surface of the pad main body 12 and the inner surfaces of the connecting portion 18 and the flange portion 20. The upper die 54 is provided so as to be rotatable with respect to the lower die 52 via a hinge 58, and is configured to open and close the upper surface opening of the lower die 52. The core die 56 is detachably provided from the upper die 54 by a driving device 60 provided on the upper die 54.

  In order to manufacture the back pad 10 using this foaming mold 50, first, the molded sheet body 28, which is three-dimensionally molded in advance, is set on the upper mold 54, and the reinforcing cloth 14 is put on the core mold 56 and is not shown. Set by fixing with pins etc. In this example, a permanent magnet 62 is provided on the upper die 54 as shown in FIG. Therefore, the magnetic sheet member 38 attached to the molding sheet body 28 is magnetically attracted to the permanent magnet 62 of the upper mold 54, so that the molding sheet body 28 is mounted at a predetermined position of the upper mold 54.

  Next, after the foamed resin stock solution 70 is injected into the lower mold 52 using an injection device (not shown), the upper mold 54 and the core mold 56 are closed with respect to the lower mold 52 as shown in FIG. Thereby, the foamed resin stock solution 70 fills the cavity 64 of the foam molding die 50 while foaming.

  At that time, the foamed resin stock solution 70 injected into the lower mold 52 is, as indicated by an arrow M in FIG. 6, from the side of the pad body 12 formed between the lower mold 52 and the core mold 56, to the core mold. It flows into the flange portion 20 side between the upper die 54 and the core die 56 so as to go around the tip of 56. Thereby, while the flange part 20 is shape | molded, the shaping | molding sheet body 28 is laminated | stacked and integrated on the outer surface 20A side.

  After foaming the back pad 10 in this way, the upper die 54 is opened, and the core die 56 is detached from the upper die 54 by the driving device 60, and then the back pad 10 is removed, whereby the back pad 10 is removed. 10 is obtained.

  In the present embodiment configured as described above, the outer surface of the flange portion 20 is formed by foam molding of a flexible polyurethane foam using the molded sheet body 28 previously formed into a shape along the outer surface 20A of the flange portion 20. By integrating with 20A, it is possible to prevent the pad surface from being damaged due to air accumulation.

  That is, by providing the molded sheet body 28 at a location corresponding to the outer surface 22A of the flange portion 20 where air accumulation easily occurs due to being higher than the parting line PL between the upper mold 54 and the core mold 56, Even if an air pool occurs, the air pool does not appear outside due to the rigid molded sheet body 28. Therefore, the defect defect in the design surface portion around the upper edge portion 2A of the backboard 2 can be prevented.

  Further, in the case of such a rigid molded sheet body 28, the portion provided with the molded sheet body 28 is formed uniformly hard, and there is no defect due to molding failure as described above. When pasting along the bent shape of the outer surface 20A, shape sag does not occur, that is, the shape of the corner portion 36 between the first surface portion 30 and the second surface portion 32 can be sharpened. Therefore, the finished appearance of the sheet with the cover material 3 covered can be improved.

  As described above, in the present embodiment, the appearance around the backboard 2 can be remarkably improved by integrating the molded sheet body 28 with the design surface portion that appears outside through the skin material 3.

  Further, in the present embodiment, since a molded felt is used as the molded sheet body 28, it is easier to reduce the occurrence of air accumulation due to the gas venting effect due to the air permeability, and the flexible polyurethane is formed on the inner surface side of the molded sheet body 28. When the foam soaks appropriately, the molded sheet body 28 can be firmly integrated with the flange portion 20.

  Further, in the present embodiment, the molded sheet body 28 includes the third surface portion 34 along the outer surface 26A of the thin portion 26, and the flange portion 20 is formed in the region from the thick portion 22 through the step portion 24 to the thin portion 26. Since it is three-dimensionally molded in a shape along the outer surface 20A, the above-described effects can be further improved and the following operational effects are also exhibited. That is, if the molded sheet body 28 includes the third surface portion 34, the third surface portion 34 is embedded when the molded sheet body 28 is not accurately mounted on the upper mold 54 and is mounted while being displaced downward. Therefore, it is possible to easily identify molding defects due to mounting misalignment depending on whether the third surface portion 34 is embedded.

  In the above-described embodiment, the example in which the protruding portion 16 including the connecting portion 18 and the flange portion 20 is provided only on the upper side portion 12A of the pad main body 12 is described, but the present invention is not limited to this. . For example, a similar inward projecting portion is provided on both the left and right side portions together with the upper side portion, and the molded sheet body is also formed on the flange portions on the left and right side portions together with the flange portion on the upper side portion. It may be formed in advance in a shape along the outer surface, and this may be integrated with the flange portion by foam molding of a flexible foam.

  Moreover, although the said embodiment demonstrated the example which provided the backboard for providing the appearance with a high-class feeling to the backrest part, for example, the backboard for providing functions, such as a table seat, to the back surface of a backrest part The present invention can also be applied to a back pad having specifications including the above. Although not enumerated one by one, various modifications can be made without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 1 ... Backrest part 2 ... Backboard 2A ... Upper edge part 10 ... Back pad 12 ... Pad main body 12A ... Upper side part 16 ... Overhang part 18 ... Connection part 20 ... Flange part 20A ... Outer surface 22 of flange part ... Thick part 22A ... Outer surface 24 of thick portion 24 ... Step portion 24A ... Outer surface 26 of step portion ... Thin portion 26A ... Outer surface 28 of thin portion ... Formed sheet body 30 ... First surface portion 32 ... Second surface portion 34 ... Third surface portion 36 ... Square portion 50 ... foaming mold 52 ... lower mold 54 ... upper mold 56 ... core mold 70 ... foamed resin stock solution L ... interval X1 ... lower Z1 ... rear Z2 ... front

Claims (4)

A back pad for a seat constituting a backrest portion of a vehicle seat having a back board on the back,
A projecting portion is integrally provided on the upper side of the back side of the pad body made of flexible foam, and the projecting portion is spaced apart from a connecting portion extending rearward from the pad body and the back surface of the pad body. A flange portion extending downward from the connecting portion,
The flange portion is formed in a thick portion on the connecting portion side, and the front end side falls to the front so as to receive the upper edge portion of the backboard. It is formed in the thin part that forms
A molded sheet body is provided on the outer surface of the flange portion, and the molded sheet body includes a first surface portion having a shape along the outer surface of the thick portion and a second surface portion having a shape along the outer surface of the stepped portion. A back pad for seats, which is three-dimensionally molded in a bent shape in advance and integrated with the outer surface of the flange portion by foam molding of the flexible foam.   The molded sheet body further includes a third surface portion having a shape along the outer surface of the thin portion, and has a shape along the outer surface of the flange portion in a region from the thick portion to the thin portion through the step portion. The back pad for sheets according to claim 1, which is three-dimensionally molded.   The sheet pad according to claim 1 or 2, wherein the molded sheet body is a thermoformed molded felt. It is a manufacturing method of the back pad for sheets given in any 1 paragraph of Claims 1-3,
A lower mold for molding the front side of the pad main body, an upper mold for molding the outer surface of the flange portion, and a core mold for molding the rear surface of the pad main body, the connecting portion and the inner surface of the flange portion. Using a foaming mold, the molded sheet body that has been three-dimensionally molded in advance is set in the upper mold, a foamed resin stock solution is injected into the lower mold, and the upper mold and the core mold are molded into the lower mold. A method for producing a back pad for a sheet, wherein the foam is closed and foam-molded.

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