JP5779941B2 - Foamed synthetic resin molded body and method for producing the same - Google Patents

Description

  The present invention relates to a foamed synthetic resin molded body comprising a molded body body made of foamed synthetic resin and an embedded member embedded in the molded body body, and in particular, the embedded member is provided with a through-hole. The present invention relates to a foamed synthetic resin molded article in which a foamed synthetic resin is contained in a through hole. Moreover, this invention relates to the manufacturing method of this foaming synthetic resin molding.

  A vehicle seat or a seat such as a sofa installed in a house includes a seat pad made of a foamed synthetic resin such as a soft polyurethane foam or a semi-rigid polyurethane foam, and a skin material mounted on the surface of the seat pad.

  In order to improve the cushion performance and functionality of the seat pad, various members may be embedded in the seat pad.

  Patent Document 1 (Japanese Patent Application Laid-Open No. 2008-259559) discloses a polyurethane foam constituting the seating portion on both sides of the seating portion of the seatpad for the purpose of improving the stability at the time of seating of the seatpad. Also, it is described that a hard member (hereinafter referred to as an embedded member) is embedded.

  In Patent Document 1, the embedded member is provided with a through-hole that vertically penetrates the embedded member. At the time of foam molding of the seat pad, the polyurethane foam is filled into the upper side of the embedded member from the lower side of the embedded member through the through hole in the mold. It is prevented from occurring.

JP 2008-259559 A

  When the embedded member is embedded in the seat pad so as to be partially exposed to the outside of the seat pad, the holding force of the embedded member by the seat pad may be weakened.

  In the above-mentioned Patent Document 1, when the embedded member is embedded in the seat pad so as to be partially exposed to the outside of the seat pad, it is completely described that the holding force of the embedded member by the seat pad is improved. There is no.

  The present invention provides a foamed synthetic resin molded body embedded in the molded body so that the embedded member is partially exposed to the outside of the molded body, and the holding power of the embedded member by the molded body is sufficiently high. It is an object of the present invention to provide a foamed synthetic resin molded article that can be produced and a method for producing the foamed synthetic resin molded article.

A foamed synthetic resin molded body of the present invention (Claim 1) is a foamed synthetic resin molded body comprising a molded body main body made of a foamed synthetic resin and an embedded member embedded in the molded body main body. In the foamed synthetic resin molded body in which the member is provided with a through-hole, and the foamed synthetic resin is contained in the through-hole, the embedded member has an exposed portion that is partially exposed to the outside of the molded body. The other part is a non-exposed part buried in the inside of the molded body, and the end portions of the through holes are respectively disposed in the non-exposed part , and the penetration The cross-sectional area of the hole is 20 mm ² or more, and the length of the through hole in the axial direction is larger than the width of the through hole .
The foamed synthetic resin molded body of the present invention (Claim 2) is a foamed synthetic resin molded body comprising a molded body body made of a foamed synthetic resin and an embedded member embedded in the molded body body, In the foamed synthetic resin molded body in which the embedded member is provided with a through-hole, and the foamed synthetic resin is contained in the through-hole, the embedded member is an exposed part of the molded body main body exposed to the outside. The other part is a non-exposed part buried in the interior of the molded body, and the end portions of the through holes are respectively disposed in the non-exposed part, and The through hole (i) has a shape that is bent or curved inside the embedded member, or (ii) is branched into at least three-pronged shape inside the embedded member, and communicates with each other. It has a shape having at least three ends. It is characterized in.

Foamed synthetic resin molded article according to claim 3, in claim 1 or 2, wherein the foamed synthetic resin is urethane foam, a part of the surface of at least the non-exposed portion of the embedded member and characterized by consisting of polypropylene To do.

  According to a third aspect of the present invention, in the foamed synthetic resin molded body according to the first or second aspect, the through hole has at least three end portions communicating with each other.

  A foamed synthetic resin molding according to a fourth aspect is characterized in that, in any one of the first to third aspects, the embedded member is provided with a plurality of the through holes.

According to a fifth aspect of the present invention, in the foamed synthetic resin molded body according to any one of the first to fourth aspects, the foamed synthetic resin molded body is a seat pad.
The foamed synthetic resin molded body according to claim 6 is the foam synthetic resin molded body according to claim 5, wherein the seat pad extends rearward from a main portion covering the front side of the back frame, and an upper side and left and right side sides of the rear surface of the main portion. A first extending portion and a second extending portion projecting from the rear end of the first extending portion to the center side of the rear surface of the main portion, the main portion, the first extending portion, and The space surrounded by the second extension part is formed with a recess into which the upper part and the left and right side parts of the back frame are respectively fitted, and an embedded member is embedded in the first extension part. A part of the side surface of the embedded member is exposed on the surface of the first extending portion on the concave portion side.
The foamed synthetic resin molded body according to claim 7 is the foam synthetic resin molded body according to claim 2, wherein the through-hole has a shape bent or curved inside the embedded member, It has a taper shape in which the opening area increases from the bent portion to the other end side.

The method for producing a foamed synthetic resin molded article according to the present invention (invention 8 ) is a method for producing the foamed synthetic resin molded article according to any one of claims 1 to 7 using a foam molding die. The embedded member attaching step for attaching the embedded member to the inner surface of the foam molding die, and after the embedded member attaching step, foamed synthetic resin is foamed in the foam molding die to form the molded body main body. A foam molding step of molding, wherein in the foam molding step, the unexposed portion of the embedded member is embedded in the foamed synthetic resin, and the through-hole is filled with the foamed synthetic resin. To do.

According to a ninth aspect of the present invention, there is provided a method for producing a foamed synthetic resin molded body according to the eighth aspect , wherein the embedded member is attached to the inner surface of the foam molding die through the exposed portion.

In the foamed synthetic resin molded article of the present invention (Claim 1 or Claim 2 ), the foamed synthetic resin is filled in the through hole provided in the embedded member, and the foamed synthetic resin in the through hole is provided. Is continuous with the foamed synthetic resin around the embedded member through the end of the through hole. As described in claim 1, the cross-sectional area of the through hole is 20 mm ² or more, and the length of the through hole in the axial direction is larger than the width of the through hole. Due to the foamed synthetic resin in the through hole, the movement of the embedded member in the direction of withdrawal from the molded body is restricted. Thereby, the holding force of the embedded member by the molded body is increased, and the dropping of the embedded member from the molded body is more reliably prevented.

According to the present invention, not only the adhesion force between the outer surface of the non-exposed portion of the embedded member and the molded body, but also the adhesion force between the inner surface of the through hole and the foamed synthetic resin filled in the through hole, and the The embedded member is held on the molded body by the restraining force of the embedded member made of the foamed synthetic resin filled in the through hole. Therefore, for example, as in claim 3 , when the molded body is made of urethane foam, and at least part of the surface of the unexposed portion of the embedded member is made of polypropylene having relatively low adhesiveness to urethane foam However, the embedded member can be held in the molded body main body with a sufficient holding force.

As described in claim 2 , (i) having a bent or curved shape inside the embedded member, or (ii) branching at least in a trifurcated shape inside the embedded member, and communicating with each other. In the case of the shape having at least three end portions, the foamed synthetic resin filled in the through hole becomes difficult to shift in the through hole. Further, in this case, since the entire length of the through hole is increased, the contact area between the inner surface of the through hole and the foamed synthetic resin in the through hole is increased. Holding power is further improved.

  As described in claim 4, by providing a plurality of through holes in the embedded member and filling each through hole with foamed synthetic resin, the holding force of the embedded member by the molded body can be further improved. .

  As described in claim 5, the foamed synthetic resin molding of the present invention is suitable for a seat pad.

According to the method for producing a foamed synthetic resin molded body of the present invention (invention 8 ), the non-exposed portion of the embedded member is embedded in the molded body, and the through-hole of the non-exposed portion is filled with the foamed synthetic resin. Thus, it is possible to manufacture a foamed synthetic resin molded body in which the embedded member partially exposed to the outside of the molded body is firmly integrated with the molded body.

Since the exposed portion of the embedded member is not embedded in the molded body, the embedded member is embedded through the exposed portion as described in claim 8 when the embedded member is attached to the inner surface of a foam molding die (hereinafter abbreviated as a mold). The member can be directly attached to the inner surface of the mold. Thereby, the embedded member can be easily and firmly attached to the inner surface of the mold.

It is an elevational view of the foamed synthetic resin molding according to the embodiment. It is sectional drawing which follows the II-II line of FIG. It is sectional drawing in the middle of the foaming of the foaming mold used for manufacturing the foaming synthetic resin molding of FIG. It is sectional drawing of the foaming synthetic resin molding which concerns on embodiment. It is sectional drawing in the middle of the foam molding of the foaming mold used for manufacturing the foamed synthetic resin molding of FIG. It is sectional drawing of the foaming synthetic resin molding which concerns on embodiment. It is sectional drawing in the middle of foam molding of the foaming mold used for manufacturing the foamed synthetic resin molding of FIG. It is an elevational view of the foamed synthetic resin molding according to the embodiment. It is sectional drawing which follows the IX-IX line of FIG. It is sectional drawing in the middle of the foaming of the foaming mold used for manufacturing the foamed synthetic resin molding of FIG.

  Hereinafter, embodiments will be described with reference to the drawings. In the following embodiments, a vehicle seat pad is exemplified as the foamed synthetic resin molded body, but the present invention is other than the foamed synthetic resin molded body constituting the seat pad other than the vehicle and the seat pad. It is also applicable to the foamed synthetic resin molded article.

[First Embodiment]
FIG. 1 is an elevation view of a seat pad as a foamed synthetic resin molding according to an embodiment, and is a view of the seat pad as viewed from the rear side. FIG. 2 is a sectional view taken along line II-II in FIG. FIG. 3 is a cross-sectional view in the middle of foam molding of a foam molding die (hereinafter abbreviated as a mold) used to manufacture the seat pad. FIG. 3 shows a cross section of a portion corresponding to FIG. 2 of this mold. In the following description, the up / down direction, the left / right direction, and the front / rear direction are the same as the up / down direction, the left / right direction, and the front / rear direction for a seated person of a seat configured using the seat pad.

  A seat pad 1 as a foamed synthetic resin molded body in this embodiment is a back pad that constitutes a backrest portion of a vehicle seat. The seat pad 1 includes a seat pad main body 2 made of a foamed synthetic resin such as polyurethane foam, and an embedded member 10 embedded in the seat pad main body 2. The embedded member 10 is integrated with the seat pad body 2 by insert molding. In this embodiment, the embedded member 10 is for absorbing a collision in the event of a collision from the side of the vehicle, but is not limited to this. The seat pad 1 is attached to a back frame (not shown) of a seat, and an outer surface is covered with a skin material (not shown). In this embodiment, the seat pad 1 is for the left seat of the vehicle, but it can also be used for the right seat by reversing the configuration.

  As shown in FIGS. 1 and 2, the seat pad body 2 includes a main body 3 that covers the front side of the back frame, and a first extension that extends rearward from the upper side and the left and right sides of the rear surface of the main body 3. Part 4 and a second extending part 5 projecting from the rear end of the first extending part 4 toward the center of the rear surface of the main part 3. The main body 3, the first extension 4, and the second extension 5 are integrally formed. Moreover, the 1st extension part 4 and the 2nd extension part 5 are continuously formed along the upper side of the rear surface of the main-body part 3, and the right-and-left side. A space surrounded by the main body 3, the first extension 4, and the second extension 5 is a recess 6 into which the upper part and the left and right sides of the back frame are fitted. The recess 6 is open toward the center of the rear surface of the main body 3.

  In this embodiment, an embedded member 10 is embedded in the first extending portion 4 on the left side of the seat pad body 2 (hereinafter referred to as the left first extending portion 4). In this embodiment, as shown in FIG. 2, a part of the right side surface 10 a of the embedded member 10 is a surface on the concave portion 6 side of the left first extending portion 4 (hereinafter referred to as the inner side surface of the left first extending portion 4). .) Is exposed. Hereinafter, when it is simply referred to as the right side surface 10 a of the embedded member 10, it refers to a portion exposed on the inner side surface of the left side first extending portion 4. The right side surface 10 a of the embedded member 10 is flush with the inner side surface of the left first extending portion 4. Portions other than the right side surface 10 a of the embedded member 10 are buried in the first left extension 4. That is, in this embodiment, the right side surface 10a of the outer surface of the embedded member 10 corresponds to the exposed portion in claim 1, and the other portions correspond to the non-exposed portion in claim 1.

  The embedded member 10 is provided with a through hole 11 that penetrates the embedded member 10. In this embodiment, the embedded member 10 is provided with three through holes 11 spaced in the vertical direction. Each through-hole 11 is provided so that both ends are located in the non-exposed portion of the embedded member 10 (that is, the portion other than the right side surface 10a).

  In this embodiment, each through-hole 11 passes through the embedded member 10 in the front-rear direction (the front-rear direction of the seat pad 1 and the vertical direction in FIGS. 2 and 3). One end side of the hole 11 in the axial center line direction opens to the front surface (lower surface in FIGS. 2 and 3) of the embedded member 10, and the other end side is the rear surface (upper surface in FIGS. 2 and 3). Is open.

In this embodiment, each through hole 11 penetrates the embedded member 10 in a straight line. In this embodiment, the through holes 11 are not in communication with each other. In this embodiment, the cross-sectional shape (hereinafter abbreviated as the cross-sectional shape) of each through-hole 11 in the direction orthogonal to the axial center line is substantially circular. The cross-sectional area of each through-hole 11 (the opening area in the cross-section perpendicular to the axial center line of each through-hole 11) is the type of foamed synthetic resin constituting the seat pad body 2 and the thickness of the embedded member 10 in the front-rear direction. However, it is preferably 20 mm ² or more, particularly 75 mm ² or more. By setting the cross-sectional area of each through-hole 11 within this numerical range, the foamed synthetic resin can easily enter the through-hole, and the effect of being able to hold the embedded member more firmly by the molded body is exhibited. .

  The shape, number and arrangement of the through holes 11 are not limited to this. For example, one, two, or four or more through holes 11 may be provided in the embedded member 10. By providing a plurality of through holes 11 in the embedded member 10, the holding force of the embedded member 10 by the seat pad main body 2 is improved, and the embedded member having the foamed synthetic resin that has entered the through hole 11 as a rotation shaft. 10 rotations can be prevented. The through holes 11 may communicate with each other. The cross-sectional shape of each through hole 11 may be a shape other than a circle, such as an oval or a polygon. By making the cross-sectional shape of the through-hole 11 into an elongated shape such as an oval, it is possible to more effectively prevent the embedded member 10 from turning about the foamed synthetic resin that has entered the through-hole 11. it can. Each through hole 11 may be bent or curved in the embedded member 10. Each through hole 11 may be branched in the middle.

  In this embodiment, at least part of the outer surface of the non-exposed portion of the embedded member 10 is made of polypropylene. The entire embedded member 10 may be made of polypropylene. The constituent material of the embedded member 10 is not limited to polypropylene.

  Next, the metal mold | die 20 for shape | molding the seat pad 1 is demonstrated. As shown in FIG. 3, in this embodiment, the mold 20 has a lower mold 21, an upper mold 22, and a middle mold 23 set on the upper mold 22. In this embodiment, the seat pad 1 is molded in the mold 20 in a posture with its front surface facing downward. That is, the front surface side of the seat pad 1 is molded by the lower mold 21, and the rear surface side of the seat pad 1 is molded by the upper mold 22 and the middle mold 23. Hereinafter, unless otherwise specified, the up-down direction and the left-right direction of the mold 20 refer to the up-down direction and the left-right direction in FIG. 3, and the up-down direction, left-right direction, and front-rear direction of the seat pad 1 are as described above. It refers to the up-down direction, the left-right direction, and the front-rear direction for a seated person of a seat configured using the seat pad 1.

A projecting portion 24 for projecting the recess 6 on the rear surface side of the seat pad main body 2 is projected from the side surface of the middle mold 23 to the side. This protrusion 24 protrudes continuously from the middle mold 23 in three directions in order to form the recess 6 continuously on the upper side of the rear surface of the seat pad body 2 and on both the left and right sides. The main body 3 of the seat pad main body 2 is formed by the cavity space S ₁ between the cavity bottom surface of the lower mold 21 and the lower surface of the middle mold 23, and the front end surface in the protruding direction of the protruding portion 24 and the cavity side surface of the lower mold 21. The first extending portion 4 is formed by the cavity space S ₂ therebetween, and the second extending portion 5 is formed by the cavity space S ₃ between the upper surface of the projecting portion 24 and the cavity ceiling surface of the upper mold 22. . The distal end surface of the projecting portion 24 facing the cavity space S ₂ for molding the left first extending portion 4, the attachment means of clips or magnets, etc. for attaching the burying member 10 (not shown) is provided .

When the seat pad 1 (seat pad main body 2) is molded using this mold 20, first, the lower mold 21 and the upper mold 22 are opened, and the cavity space for molding the left first extending portion 4 is formed. by the attachment means on the tip surface of the projecting portion 24 facing the S ₂ mounting the buried member 10. In this embodiment, since the right side surface 10a of the embedded member 10 is exposed to the outside of the seat pad main body 2, the right side surface 10a is directly joined to the distal end surface of the protruding portion 24. The embedded member 10 can be attached. Thereby, the embedded member 10 can be easily and firmly attached to the distal end surface of the protruding portion 24.

Next, a foamed synthetic resin material is injected into the lower mold 21 and the lower mold 21 and the upper mold 22 are clamped. In this embodiment, as shown in FIG. ₂ , in the cavity space S2 after clamping, each through hole 11 extends so as to penetrate the embedded member 10 in the vertical direction. Thereafter, the foamed synthetic resin raw material is heated and foamed. This foamed synthetic resin fills the cavity spaces S ₁ , S ₂ , S ₃ in this order as shown by arrow B in FIG. Thereby, the main body part 3, the first extension part 4, and the second extension part 5 of the seat pad main body 2 are integrally formed.

At this time, part of the foamed synthetic resin which has flowed into a cavity S ₂ for the cavity S ₁ to forming the left first extending portion 4, the lower side of the embedded member 10 (lower side in the die 20) From the inside of each through-hole 11, filling each through-hole 11 toward its upper end side (upper end side in the mold 20), and after passing through each through-hole 11, the upper side of the embedded member 10 ( On the upper side in the mold 20, the remaining portion of the foamed synthetic resin that has passed through the cavity space S ₂ around the embedded member 10 joins. Thereby, the foamed synthetic resin is also filled in each through hole 11. The foamed synthetic resin in each through-hole 11 is continuous with the foamed synthetic resin around the embedded member 10 on both end sides of each through-hole 11.

  After the foamed synthetic resin is cured, the mold is opened and the seat pad 1 is removed. Then, the seat pad 1 is completed by performing the finishing process of the surface of the seat pad main body 2 as needed.

  In the seat pad 1 manufactured in this way, each of the through holes 11 provided in the embedded member 10 is filled with foamed synthetic resin, and both end sides of the foamed synthetic resin in each through hole 11 are Since each of them is continuous with the foamed synthetic resin around the embedded member 10, the seat pad body 2 of the embedded member 10 (the inner surface of the left first extending portion 4) is formed by the foamed synthetic resin in the through hole 11. Movement in the direction of exiting from is restricted. As a result, the holding force of the embedded member 10 by the seat pad main body 2 becomes high, and the dropping of the embedded member 10 from the seat pad main body 2 is more reliably prevented.

  According to the present invention, not only the adhesive force between the outer surface of the embedded member 10 and the seat pad body 2, but also the adhesive force between the inner surface of the through hole 11 and the foamed synthetic resin filled in the through hole 11, The embedded member 10 is held by the seat pad body 2 by the restraining force of the embedded member 10 made of foamed synthetic resin filled in the through hole 11. Therefore, as in this embodiment, even if a part of the outer surface of at least the non-exposed portion of the embedded member 10 is made of polypropylene having a relatively low adhesiveness with the polyurethane constituting the seat pad body 2, The embedded member 10 can be held on the seat pad body 2 with a sufficient holding force.

  In this embodiment, each through-hole 11 passes through the embedded member 10 in a direction substantially perpendicular to the direction in which the embedded member 10 is pulled out from the seat pad body 2, and the foamed synthetic resin filled in the through-hole 11 Since it comes to oppose the withdrawal of the embedded member 10 from the seat pad main body 2 as a whole, the embedded member 10 is more easily detached from the seat pad main body 2.

  In this embodiment, since three through holes 11 are provided in the embedded member 10 and each through hole 11 is filled with foamed synthetic resin, the holding force of the embedded member 10 by the seat pad body 2 is higher. It will be a thing.

[Second Embodiment]
FIG. 4 is a cross-sectional view of the vicinity of an embedded member of a seat pad as a foamed synthetic resin molded body according to another embodiment. FIG. 5 is a sectional view in the middle of foam molding of a mold used to manufacture the seat pad. 4 and 5 show cross sections of the same parts as in FIGS.

  In the first embodiment described above, the through-hole 11 penetrates the embedded member 10 in a straight line in the front-rear direction, and both end sides thereof are opened on the front surface and the rear surface of the embedded member 10. The shape of the hole 11 and the arrangement on both ends thereof are not limited to this.

  In the embedded member 10A according to this embodiment, the through hole 11 is bent or curved into a substantially “L” shape or a substantially “<” shape inside the embedded member 10A, and has one end side thereof. Is disposed on the front surface of the embedded member 10A (the front surface for the seat occupant configured using the seat pad 1 and the lower surface in FIGS. 4 and 5), and the other end is the left side surface of the embedded member 10A. 10b.

  The other end side of the through hole 11 from the bent portion inside the embedded member 10A is closer to the left side surface 10b of the embedded member 10A, and the rear surface of the embedded member 10A (the sheet formed using the seat pad 1) It extends obliquely so as to approach the rear surface side for the seated person and the upper surface side in FIGS. Further, the other end side from the bent portion of the through hole 11 has a tapered shape in which the opening area increases as the left side surface 10b of the embedded member 10A is approached. This is to allow the foamed synthetic resin to smoothly flow through the through hole 11 from the one end side to the other end side during foam molding of the seat pad 1.

  Other configurations in this embodiment are the same as those in the first embodiment described above. In FIGS. 4 and 5, the same reference numerals as those in FIGS. 1 to 3 denote the same parts.

  The manufacturing method of the seat pad 1 in this embodiment is the same as that of the first embodiment.

In this embodiment, the foam molding process of the seat pad main body 2, a portion of the foamed synthetic resin which has flowed into a cavity S ₂ for molding the left first extending portion 4 from the cavity S _1, 5 As shown by an arrow B in the figure, after entering the through hole 11 from the lower side of the embedded member 10A (the lower side in the mold 20) and filling the through hole 11, the left side surface 10b of the embedded member 10A was opened. It flows into the through hole 11 out of the end portion of the through hole 11, and merges with the remainder of the foamed synthetic resin passing through the cavity space S ₂ around the embedded member 10A. Thereby, the foamed synthetic resin is filled into the through hole 11, and the foamed synthetic resin in the through hole 11 is continuous with the foamed synthetic resin around the embedded member 10 </ b> A at both ends of the through hole 11.

  As in this embodiment, by making the through hole 11 bend in the embedded member 10 </ b> A, the foamed synthetic resin filled in the through hole 11 is less likely to shift in the through hole 11. Therefore, the restraining force of the embedded member 10A by the foamed synthetic resin in the through hole 11 is improved.

[Third Embodiment]
FIG. 6 is a cross-sectional view of the vicinity of an embedded member of a seat pad as a foamed synthetic resin molded body according to another embodiment. FIG. 7 is a cross-sectional view of the mold used for manufacturing the seat pad in the middle of foam molding. 6 and 7 show cross sections of the same parts as in FIGS.

  In the embedded member 10B in this embodiment, the through hole 11 is branched inside the embedded member 10B.

  In this embodiment, the through-hole 11 branches into a trifurcated shape inside the embedded member 10B, and has three end openings that communicate with each other. In this embodiment, the first end opening of the through hole 11 is formed on the front surface of the embedded member 10B (the front surface for the seat occupant configured using the seat pad 1 and the lower surface in FIG. 6). And the second end opening of the through hole 11 is disposed on the left side surface 10b of the embedded member 10B, and the rear surface of the embedded member 10B (which is a rear surface for a seated person configured with the seat pad 1). Thus, the third end opening of the through hole 11 is disposed on the upper surface in FIG. The shape of the through hole 11 and the number and arrangement of the end openings are not limited to this.

  Other configurations in this embodiment are the same as those in the first embodiment described above. In FIGS. 6 and 7, the same reference numerals as those in FIGS. 1 to 3 denote the same parts.

  The manufacturing method of the seat pad 1 in this embodiment is the same as that of the first embodiment.

In this embodiment, the foam molding process of the seat pad main body 2, a portion of the foamed synthetic resin which has flowed into a cavity S ₂ for molding the left first extending portion 4 from the cavity S _1, 7 As shown by the arrow B in the figure, the through hole 11 (first end opening) enters from the lower side of the embedded member 10B (the lower side in the mold 20), and the through hole 11 is filled. When the foamed synthetic resin reaches the branch point of the through hole 11, a part of the foamed synthetic resin goes to the second end opening, and the other part goes to the third end opening. Thereafter, these foamed synthetic resin, and flows out through holes 11 from the second end opening, and a third end opening, respectively, foamed synthetic in passes around the cavity S ₂ of the embedded member 10B resins, as well, to join the foamed synthetic resin which has flowed in the cavity space S ₂ to the upper side of the embedded member 10B. Accordingly, the foamed synthetic resin is filled into the through hole 11 in a trifurcated shape. Further, the foamed synthetic resin in the through-hole 11 is continuous with the foamed synthetic resin around the embedded member 10 </ b> B through each end opening of the through-hole 11.

  As in this embodiment, by forming the through-hole 11 into a branched shape, the foamed synthetic resin filled in the through-hole 11 is less likely to shift within the through-hole 11. Further, since the entire length of the through-hole 11 is longer than that of the non-branched one, the contact area between the inner surface of the through-hole 11 and the foamed synthetic resin in the through-hole 11 is increased, and their adhesive strength is increased. As a result, the holding force of the embedded member 10B by the seat pad main body 2 is improved.

[Fourth Embodiment]
FIG. 8 is an elevation view of a seat pad as a foamed synthetic resin molding according to another embodiment, and is a view of the seat pad as seen from the rear side. FIG. 9 is a sectional view taken along line IX-IX in FIG. FIG. 10 is a cross-sectional view of the mold used for manufacturing the seat pad in the middle of foam molding. FIG. 10 shows a cross section of the part corresponding to FIG. 9 of this mold.

  In each of the embodiments described above, the embedded members 10, 10 </ b> A, 10 </ b> B are such that only the right side surface 10 a is exposed to the outside of the seat pad body 2. It may be exposed to the outside.

  The embedded member 10 </ b> C in this embodiment has a lateral width equal to that of the left first extending portion 4 of the seat pad main body 2, and a part of the right side surface 10 a thereof is the left first extending portion 4. The left side surface 10b is exposed to the inner side surface, and a part of the left side surface 10b is exposed to the surface opposite to the concave portion 6 of the left side first extending portion 4 (hereinafter referred to as the outer side surface of the left side first extending portion 4). doing. Hereinafter, when the right side surface 10a and the left side surface 10b of the embedded member 10C are simply referred to, the portions exposed on the inner side surface and the outer side surface of the left first extending portion 4 are referred to. The right side surface 10a of the embedded member 10C is flush with the inner side surface of the left first extending portion 4, and the left side surface 10b is flush with the outer side surface of the left first extending portion 4. Yes. Portions other than the right side surface 10a and the left side surface 10b of the embedded member 10C are buried in the left first extending portion 4. That is, in this embodiment, among the outer surfaces of the embedded member 10C, the right side surface 10a and the left side surface 10b correspond to the exposed portion in claim 1, and the other portions correspond to the non-exposed portion in claim 1.

  In this embodiment, the through hole 11 is provided so as to penetrate the embedded member 10 </ b> C in the front-rear direction of the seat pad 1. Also in this embodiment, the through hole 11 may be bent or curved in the middle, or may have a shape branched in the middle. In any case, the through hole 11 is provided such that each end portion is located in a non-exposed portion (that is, a portion other than the right side surface 10a and the left side surface 10b) of the embedded member 10C.

  Other configurations in this embodiment are the same as those in the first embodiment described above. In FIGS. 8 to 10, the same reference numerals as those in FIGS. 1 to 3 denote the same parts.

  The manufacturing method of the seat pad 1 in this embodiment is the same as that of the first embodiment.

In this embodiment, the foam molding process of the seat pad main body 2, of the 10 views of arrow B as, the embedded member 10C that arranged in the cavity space S in ₂ for molding the left first extending portion 4 the through hole 11, the lower side of the embedded member 10C, i.e. foamed synthetic resin flows from the cavity S ₁ side, filling the through hole 11 the foamed synthetic resin toward the upper end side of the through hole 11 To go. Thereafter, the foamed synthetic resin flows out from the through-hole within 11 the top of the cavity space S _2, and then continue to fill the upper and the cavity space S ₃ of the cavity S _2. Thereby, the foamed synthetic resin is filled into the through hole 11. In addition, the foamed synthetic resin in the through hole 11 is continuous with the foamed synthetic resin around the embedded member 10 </ b> C on both end sides of the through hole 11.

  Also in this embodiment, the foamed synthetic resin is filled in the through hole 11 of the embedded member 10C, and the both ends of the foamed synthetic resin in each through hole 11 are the same as the foamed synthetic resin around the embedded member 10C, respectively. Since it is continuous, the foamed synthetic resin in the through-hole 11 restrains the movement of the embedded member 10 </ b> C from the seat pad main body 2 (the inner side surface and the outer side surface of the left first extending portion 4) in the pull-out direction. The Thereby, the holding force of the embedded member 10C by the seat pad main body 2 becomes high, and the dropping of the embedded member 10C from the seat pad main body 2 is more reliably prevented.

  Each of the above configurations is an example of the present invention, and the present invention may have configurations other than those described above.

  For example, in the above-described embodiment, the embedded members 10 and 10A to 10C are all embedded in the first left extension 4 of the seat pad body 2, but the embedded position of the embedded member is not limited to this. .

  Although the above embodiment shows an application example of the present invention to a seat pad, the present invention is also applicable to a foamed synthetic resin molded body other than the seat pad.

DESCRIPTION OF SYMBOLS 1 Seat pad 2 Seat pad main body 3 Main part 4 1st extension part 5 2nd extension part 6 Recessed part 10,10A-10C Embedded member 11 Through-hole 20 Mold 21 Lower mold 22 Upper mold 23 Middle mold

Claims (9)

A molded body made of foamed synthetic resin;
A foamed synthetic resin molded body comprising an embedded member embedded in the molded body,
In the foamed synthetic resin molded body in which a through hole is provided in the embedded member, and the foamed synthetic resin enters the through hole,
The embedded member is an exposed part that is partly exposed to the outside of the molded body, and the other part is a non-exposed part that is buried inside the molded body.
The end portions of the through-holes are respectively disposed in the non-exposed portions, the cross-sectional area of the through-holes is 20 mm ² or more, and the length of the through-hole in the axial center line direction is A foamed synthetic resin molded article characterized by being larger than the width of the through hole. A molded body made of foamed synthetic resin;
A foamed synthetic resin molded body comprising an embedded member embedded in the molded body,
In the foamed synthetic resin molded body in which a through hole is provided in the embedded member, and the foamed synthetic resin enters the through hole,
The embedded member is an exposed part that is partly exposed to the outside of the molded body, and the other part is a non-exposed part that is buried inside the molded body.
The end portions of the through holes are respectively disposed in the non-exposed portions, and the through holes (i) have a shape that is bent or curved inside the embedded member and penetrates the through holes. Or (ii) a foamed synthetic resin characterized by having a shape having at least three ends branched into at least three-pronged shapes inside the embedded member. Molded body. In Claim 1 or 2, the foamed synthetic resin is urethane foam,
A foamed synthetic resin molded body, wherein at least a part of the surface of the unexposed portion of the embedded member is made of polypropylene.   The foamed synthetic resin molded body according to any one of claims 1 to 3, wherein the embedded member is provided with a plurality of the through holes.   The foamed synthetic resin molded body according to any one of claims 1 to 4, wherein the foamed synthetic resin molded body is a seat pad.   6. The seat pad according to claim 5, wherein the seat pad includes a main body that covers the front side of the back frame, a first extension that extends rearward from the upper side and the left and right sides of the rear surface of the main body, and the first pad. A second extending portion projecting from the rear end of the extending portion to the center of the rear surface of the main portion, and a space surrounded by the main portion, the first extending portion, and the second extending portion. Is formed with recesses into which the upper part and the left and right side parts of the back frame are respectively fitted, and an embedded member is embedded in the first extension part, and the recess part side surface of the first extension part is formed. Is a foamed synthetic resin molded body in which a part of the side surface of the embedded member is exposed. The through hole according to claim 2, wherein (i) the through hole has a bent or curved shape inside the embedded member, and has an opening area from the bent portion to the other end side of the through hole. A foamed synthetic resin molded article having a taper shape that becomes larger. A method for producing a foamed synthetic resin molded article according to any one of claims 1 to 7, using a foam molding die,
An embedded member attaching step of attaching the embedded member to the inner surface of the foam molding die;
After the embedded member attaching step, performing a foam molding step of foaming a foamed synthetic resin in the foam molding die to mold the molded body,
In the foam molding step, the non-exposed portion of the embedded member is embedded in the foamed synthetic resin, and the foamed synthetic resin is filled in the through hole. .   9. The method for producing a foamed synthetic resin molded body according to claim 8, wherein the embedded member is attached to an inner surface of the foam molding die through the exposed portion.

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