JP5807357B2 - Foamed synthetic resin molding - Google Patents

Description

  The present invention relates to a foamed synthetic resin molded body in which a main body portion and an extending portion extending from the main body portion are integrally formed. Particularly, in use, the extended portion approaches the main body portion at the distal end side. It is related with the foaming synthetic resin molding used by making it deform | transform.

  In general, a seat for a vehicle or a sofa installed in a house includes a seat pad made of a foamed synthetic resin such as a flexible polyurethane foam or a semi-rigid polyurethane foam, a seat frame that supports the seat pad, And a skin material to be applied to the outer surface of the seat pad.

  FIG. 6 is a longitudinal sectional view of a seat pad according to a conventional example, and FIG. 7 is a longitudinal sectional view of an essential part of a mold for molding the seat pad.

  The seat pad 100 includes a main body part 101 that comes into contact with a seated person, a first extension part 102 that extends from the peripheral part of the main body part 101 to the back surface side of the main body part 101, and the first extension part 102. A second extending portion 103 extending from the front end side in the extending direction to the center side of the back surface of the main body portion 101, and surrounded by the main body portion 101, the first extending portion 102, and the second extending portion 103. The seat frame 120 (see FIG. 11) is engaged with the recessed portion 104. The main body part 101, the first extension part 102, and the second extension part 103 are integrally formed. A reinforcing cloth 105 is disposed along the back surface of the main body portion 101 and the surface of the first extension portion 102 and the second extension portion 103 on the recess 104 side.

A mold 110 for foam-molding the seat pad 100 includes an upper mold 111, a lower mold 112, and a middle mold 113 set on the upper mold 111. The front surface (seat-side surface) side of the seat pad 100 is formed by the cavity surface of the lower mold 112, and the back surface side of the seat pad 100 is formed by the cavity surfaces of the upper mold 111 and the middle mold 113. A projecting portion 114 for forming the recess 104 is projected from the side surface of the middle mold 113. A main body portion 101 of the seat pad 100 is formed by a cavity space S ₁₀₁ between the bottom surface of the cavity of the lower die 112 and the lower surface of the middle die 113, and the front end surface in the protruding direction of the protruding portion 114 and the cavity side surface of the lower die 112. the first extending portion 102 by a cavity _{S 102} between the molding, the second extending portion 103 is molded by the cavity _{S 103} between the cavity ceiling surface of the upper surface and the upper mold 111 of the projecting portion 114 The

When foam-molding the seat pad 100, the reinforcing material 105 is attached to the middle mold 113, the foam synthetic resin raw material 115 is injected into the lower mold 112, and the upper mold 111 and the lower mold 112 are clamped to perform the foam synthesis. The resin raw material 115 is heated and foamed. The foamed synthetic resin raw material 115 fills the cavity spaces S ₁₀₂ and S ₁₀₃ in this order from the cavity space S _{101 as} the foaming proceeds. Thereby, the main-body part 101, the 1st extension part 102, and the 2nd extension part 103 are integrally formed. Further, the reinforcing material 105 is integrated with these back surfaces (the surfaces facing the inside of the recess 104 in the first extension portion 102 and the second extension portion 103). The gas in the mold 110 includes a parting line 116 between the upper mold 111 and the lower mold 112 located on the base end side in the extending direction of the second extending portion 103 (hereinafter referred to as the base end side), and The second extending portion 103 is discharged out of the mold 110 through a parting line 117 between the upper mold 111 and the middle mold 113 located on the front end side (hereinafter referred to as the front end side) in the extending direction. The

As shown in FIG. 6, the surface of the second extending portion 103 opposite to the main body portion 101 is curved convexly away from the main body portion 101, and the second extending portion 103 extends in the extending direction. middle section, if that is the maximum bulging portion 103a which began bulge separating direction from the most main body 101, as Figure 7, the parting line of the cavity ceiling surface of the upper mold 111 facing the cavity S ₁₀₃ The part between 116 and 117 becomes the concave-shaped part 111a bent upwards. In the concave portion 111 a, the cavity ceiling surface of the upper mold 111 is higher than the parting lines 116 and 117. In this case, gas tends to remain in the concave portion 111a, and there is a possibility that a defective molding such as a void (a chip of a product) may occur in the second extending portion 103.

  In Patent Document 1 (Japanese Patent Application Laid-Open No. 2009-90549), the second extending portion 103 is formed by foaming the seat pad in a shape in which the second extending portion 103 is separated from the back surface of the main portion 101 toward the distal end side. 103 describes that formation defects such as voids are prevented. 8 is a perspective view of the seat pad of Patent Document 1, FIG. 9 is a cross-sectional view taken along line IX-IX of FIG. 8, and FIG. 10 is a mold for foam-molding the seat pad of Patent Document 1 FIG. 11 is a longitudinal sectional view showing a state where a seat pad of Patent Document 1 is attached to a seat frame and a skin material is attached.

  As shown in FIGS. 8 and 9, the seat pad 100 </ b> A of Patent Document 1 has a pair of slits 106 in the second extending portion 103 spaced apart in the direction orthogonal to the extending direction from the first extending portion 102. 106, the portion between the slits 106, 106 of the second extending portion 103 is raised in the direction opposite to the main body 101 than the other portion, and the tip side is closer to the tip portion. The shape is separated from the back surface of the main body 101.

In mold 110A for foam molding the seat pad 100A, as FIG. 10, the cavity _{S 103} is so shaped that the second extending portion 103 is spaced from the rear surface of the main body portion 101 as the distal end side As a whole, the slope extends upward toward the distal end side of the second extending portion 103, and the parting line 117 is positioned higher in the cavity space S ₁₀₃ than the mold 110 in FIG. 7. Therefore, the gas hardly remains in the concave portion 111a of the cavity ceiling surface, and the gas is discharged from the parting line 117 to the outside of the mold 110 relatively smoothly. As a result, formation defects such as voids in the second extending portion 103 are prevented.

  When the seat 130 is configured by using the seat pad 100A, as shown in FIG. 11, the end of the seat frame 120 is engaged with the recess 104 on the back surface side of the seat pad 100A, and the seat frame 120 is moved to the front side. The main body 101 of the seat pad 100A is disposed. Thereafter, the second extending portion 103 that has been caused to move away from the main body portion 101 is bent and deformed toward the main body portion 101 side (including curved deformation, the same applies hereinafter), and is brought into contact with the back surface of the seat frame 120. In this state, the skin material 107 is attached to the outer surface of the seat pad 100A. The second extending portion 103 is restrained by the skin material 107 so as to be in contact with the back surface of the seat frame 120. As a result, a sheet having the same shape as that when the seat pad 100 of FIG. 6 is used is configured.

JP 2009-90549 A

  In the seat pad 100A of Patent Document 1, when the second extending portion 103 is bent and deformed toward the main body 101, the second extending portion 103 slightly expands along with the bending deformation. There is a possibility that the distal end portion of the second extending portion 103 after being placed is displaced from the intended position. In order to prevent this, it is necessary to clarify by simulation or the like how much the second extending portion 103 extends with the bending deformation of the second extending portion 103, and the design becomes complicated. .

  In addition, in the seat pad 100A, the second extending portion 103 has a thick middle portion and high rigidity, so the second extending portion 103 is bent and deformed toward the main body 101 side. Hateful. Further, even after the second extending portion 103 is bent and deformed, the skin material 107 needs to have high rigidity in order to restrain the second extending portion 103.

  The present invention solves the above-described conventional problems, and can bend and deform the extension part to the main body part relatively easily and accurately with a simple configuration. It aims at providing the foaming synthetic resin molding which can maintain the state comparatively easily.

The foamed synthetic resin molded body according to claim 1 has a main body portion and an extending portion extending from the main body portion, and the foamed synthetic resin is disposed on the leading end side in the extending direction of the extending portion from the main body portion. When the foamed synthetic resin molded body is used, the main body part and the extended part are integrally molded with the foamed synthetic resin, and when the foamed synthetic resin molded body is used, In the foamed synthetic resin molded body that is used by being deformed so that the tip side approaches the main body portion, an easily deformable portion is provided in the extension portion, and the extension portion of the outer surface of the extension portion is the extension portion. When the portion is deformed so that the tip side approaches the main body portion, the surface facing the main body portion (hereinafter referred to as a surface facing the main body portion) is formed on the inner side of the extension portion. A recessed portion to be recessed is provided, and the extension portion where the recessed portion is located has a thickness in the range of 5 to 25 mm. The is characterized in that said easily deformable portion is formed.

  The foamed synthetic resin molded body according to claim 2 is the foam synthetic resin molded body according to claim 1, wherein the extension portion is deformed so that a tip side thereof approaches the main body portion, and is opposite to the main body portion of the extension portion. The surface is convexly curved away from the main body part, and the middle part of the extending part in the extending direction is the largest bulging part that bulges away from the main body part in the separating direction. The easily deformable portion is characterized in that at least a part thereof is at the same distance as the maximum bulging portion from the proximal end side in the extending direction of the extending portion toward the distal end side. .

According to a third aspect of the present invention, there is provided the foamed synthetic resin molded body according to the first aspect , wherein the concave portion has a groove shape extending in a direction orthogonal to the extending direction of the extending portion.

A foamed synthetic resin molded body according to a fourth aspect of the present invention is the foam synthetic resin molded body according to the first or third aspect, wherein the recessed portion is parallel to the extending direction of the extending portion and perpendicular to the surface of the extending portion facing the main body. The cross-sectional shape is characterized in that the width becomes narrower toward the back side of the recess.

According to a fifth aspect of the present invention, there is provided the foamed synthetic resin molded article according to the fourth aspect , wherein the bottom surface of the concave portion is convexly curved toward the inner side of the extending portion.

According to a sixth aspect of the present invention, there is provided the foamed synthetic resin molded body according to the fourth aspect , wherein the cross-sectional shape of the concave portion is a trapezoidal shape.

According to a seventh aspect of the present invention, there is provided a foamed synthetic resin molded body according to any one of the first to sixth aspects, wherein the foamed synthetic resin molded body is a seat pad.

In the foamed synthetic resin molded body of the present invention, since the easily deformable portion is provided in the extended portion, the extended portion is relatively easily approached to the main body when the foamed synthetic resin molded body is used. Can be bent and deformed, and the bent and deformed state can be maintained relatively easily. In addition, by providing the easily deformable portion in the extending portion, it is possible to absorb or suppress the extension in the extending direction of the extending portion due to the bending deformation of the extending portion by this easily deformable portion. It is possible to arrange the distal end portion of the extended portion after being made at an expected position with relatively high accuracy.
In particular, an easily deformable portion can be provided in the extension portion with a simple configuration by forming a recess on the surface of the extension portion facing the main portion. In addition, when the extension portion is bent and deformed toward the main body side, the recess is deformed so that the width in the extension direction of the extension portion is reduced. The extension of the portion in the extending direction is absorbed by the deformation of the concave portion. Thereby, the arrangement | positioning precision of the front-end | tip part of this extension part after bending-deforming the extension part to the main-body part side can be improved.

  As described in claim 2, by providing the easily deformable portion so that at least a part thereof is at the same distance as the maximum bulging portion of the extending portion from the base end side of the extending portion, the bending deformation of the extending portion is reduced. It is possible to further facilitate and further improve the arrangement accuracy of the distal end portion of the extended portion after bending deformation.

As described in claim 3 , it is preferable that the concave portion has a groove shape extending in a direction orthogonal to the extending direction of the extending portion (hereinafter referred to as the width direction of the extending portion). By comprising in this way, an extension part can be bent and deformed equally in the width direction.

As in claim 4 , the cross-sectional shape of the recess in the direction parallel to the extending direction of the extending portion and in the direction orthogonal to the surface facing the main portion of the extending portion is such that the width becomes narrower toward the back side of the recessed portion. It is preferable that By comprising in this way, at the time of shaping | molding of a foaming synthetic resin molded object, a foaming synthetic resin can get over this recessed part smoothly, and can expand | swell from the base end side of the extension part to the front end side.

In this case, as described in claim 5 , it is preferable that the bottom surface of the concave portion is a curved surface that is convexly curved toward the inner side of the extending portion. By comprising in this way, at the time of shaping | molding of a foaming synthetic resin molding, a foaming synthetic resin can get over this recessed part more smoothly. Further, as described in claim 6 , even when the cross-sectional shape of the recess is a trapezoid whose width becomes narrower toward the back, the foamed synthetic resin can get over the recess relatively smoothly.

As described in claim 7 , the foamed synthetic resin molding of the present invention is suitable for application to a seat pad.

It is sectional drawing of the seat pad as a foaming synthetic resin molding which concerns on embodiment. It is sectional drawing of the metal mold | die for manufacturing the seat pad of FIG. FIG. 2 is a cross-sectional view showing a state in which the seat pad of FIG. 1 is attached to a seat frame and a skin material is attached to the outer surface of the seat pad. It is sectional drawing which shows the other example of a recessed part which comprises an easily deformable part. It is sectional drawing which shows the other structural example of an easily deformable part. It is sectional drawing of the seat pad which concerns on a prior art example. It is sectional drawing of the metal mold | die for manufacturing the seat pad of FIG. It is a perspective view of the seat pad concerning another conventional example. It is sectional drawing which follows the IX-IX line of FIG. It is sectional drawing of the metal mold | die for manufacturing the seat pad of FIG. It is sectional drawing which shows the state with which the seat pad of FIG. 8 was attached to the seat frame, and the skin material was adhere | attached on the outer surface of this seat pad.

  Embodiments will be described below with reference to the drawings. In this embodiment, the back pad constituting the backrest portion of the vehicle seat is illustrated as the foamed synthetic resin molded body. However, the present invention is not limited to this, but the foamed synthetic resin molded body, for example, the seat of the seat. The present invention can be applied to various foamed synthetic resin moldings such as cushion pads constituting the part.

  FIG. 1 is a longitudinal sectional view of the vicinity of the upper end of a seat pad as a foamed synthetic resin molding according to an embodiment, and FIG. 2 corresponds to FIG. 1 of a mold for manufacturing the seat pad. FIG. 3 is a longitudinal sectional view of a portion corresponding to FIG. 1, showing a state in which the seat pad is attached to the seat frame and a skin material is attached to the outer surface of the seat pad. FIG. Hereinafter, 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.

  In this embodiment, the foamed synthetic resin molded body is a seat pad 1 constituting a vehicle seat. In particular, in this embodiment, the seat pad 1 is a back pad that constitutes a seat back portion 50 (FIG. 3). The seat pad 1 includes a seat pad body 2 made of a foamed synthetic resin such as polyurethane foam, and a reinforcing member 10 disposed along the rear surface of the seat pad body 2. The reinforcing material 10 is integrated with the seat pad main body 2 by integral molding. The configuration of the mold 20 for foam-molding the seat pad body 2 and the method for manufacturing the seat pad 1 using the mold 20 will be described in detail later. The seat pad 1 is attached to a seat frame (back frame) 30 of the backrest portion 50, and the outer surface is covered with a skin material 40.

  As shown in FIG. 1, the seat pad body 2 includes a main body 3 that covers the front side of the seat frame 30, 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. 4 and a second extending portion 5 that extends from the rear end of the first extending portion 4 to the center of the rear surface of the main body portion 3. In this embodiment, the series of the first extending portion 4 and the second extending portion 5 constitute the extending portion in claim 1. In FIGS. 1 and 3, only the first extending portion 4 extending from the upper side of the main portion 3 and the second extending portion 5 connected thereto are shown. 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 in which the upper side and the left and right sides of the seat frame 30 are engaged. The recess 6 is open toward the center of the rear surface of the main body 3. In addition, the structure of the main part of the seatpad main body 2 is not limited to this. The first extension part 4 and the second extension part 5 may also be provided on the lower side of the rear surface of the main part 3.

  Even in the seat pad 1, the second extending portion 5 along the upper side of the main portion 3 (hereinafter referred to as the upper second extending portion 5), similarly to the seat pad 100A shown in FIGS. Are provided with a pair of slits (not shown) spaced in the left-right direction, and the portion of the upper second extending portion 5 between these slits is behind the other portions. (The direction opposite to the main body part 3), and the tip end side is separated from the back surface of the main body part 3. Hereinafter, when it is simply referred to as the upper second extension portion 5, it refers to a portion that is caused rearward between the slits.

  A concave portion 7 constituting an easily deformable portion is provided on the front surface of the upper second extending portion 5 (the surface facing the main body portion 3). In this embodiment, the recess 7 has a groove shape extending in the left-right direction. The groove-like recess 7 is formed continuously over the entire width of the upper second extension 5, and the left and right ends of the recess 7 reach the slits, respectively. The cross-sectional shape of the concave portion 7 in the direction parallel to the extending direction of the upper second extending portion 5 and in the direction orthogonal to the front surface of the upper second extending portion 5 is such that the width becomes narrower toward the back side of the concave portion 7. It is preferable. In this embodiment, as shown in FIG. 1, the concave portion 7 has a so-called mountain-shaped cross-sectional shape in which the bottom surface is curved convexly toward the inner side of the upper second extending portion 5. Further, the corner portion where the upper side surface of the recess 7 and the front surface of the upper second extension portion 5 intersect, and the corner portion where the lower side surface of the recess 7 and the front surface of the upper second extension portion 5 intersect, Each of these surfaces has a curved shape (with an R) so that the surfaces are smoothly connected. The cross-sectional shape of the recess 7 is not limited to this.

  In this embodiment, as shown in FIG. 1, the upper second extending portion 5 has a shape in which a portion on the front end side with respect to the concave portion 7 is caused to move backward. The two-dot chain line in FIG. 1 indicates the upper second extension when the distal end side of the upper second extension portion 5 is bent and deformed forward (the main portion 3 side) and brought into contact with the rear surface of the seat frame 30. The position of the leading end side of the protruding portion 5 is shown. The front surface of the tip of the upper second extending portion 5 in a state where the upper second extending portion 5 is raised rearward, and the upper second portion in a state where the upper second extending portion 5 is bent and deformed forward. 2 The angle θ (FIG. 1) formed with the front surface of the tip of the extending portion 5 is preferably 20 ° or less, particularly about 5 to 15 °. The preferred range of θ is such that, as in the present embodiment, the first extension 4 extends in advance toward the rear of the main body 3 and the second extension 5 extends to the first extension 4. The extension part is formed in a shape extending from the tip of the main part 3 toward the center side of the rear surface of the main part 3. For example, the extension part extends upward or laterally from the main part 3 (the main part 3. This is not the case when it is shaped so as to extend in a straight line in the direction of the extension of the seating surface and is bent and deformed so that the extending portion wraps around the rear surface of the main portion 3.

  In this embodiment, the rear surface of the upper second extending portion 5 (surface opposite to the main body portion 3) is a curved surface that is convex rearward. Hereinafter, in the state in which the distal end side of the upper second extending portion 5 is bent and deformed to the main body 3 side and brought into contact with the rear surface of the seat frame 30, the rear surface is the most. The portion that bulges backward is referred to as a maximum bulge portion 5a. As shown in FIG. 3, the maximum bulging portion 5 a is located in the middle of the upper second extending portion 5 in the vertical direction. The concave portion 7 is preferably arranged so as to overlap the maximum bulging portion 5a (so that at least a part thereof is located at the same height as the maximum bulging portion 5a), and in particular, the deepest portion of the concave portion 7 is maximum. Although it is most preferable that it arrange | positions so that it may be located in the same height as the bulging part 5a, arrangement | positioning of the recessed part 7 is not limited to this. The concave portion 7 may be disposed so as to be shifted to the front end side or the rear end side of the upper second extending portion 5 with respect to the maximum bulging portion 5a. In this case, if the distance from the tip of the upper second extending portion 5 to the maximum bulging portion 5a is L, the concave portion 7 is 50 to 150% of this L from the tip of the upper second extending portion 5, particularly 75. It is preferable to have a separation of ~ 125%. In addition, it is preferable that the recessed part 7 is arrange | positioned in the position which does not interfere with this seat frame 30, when the front end side of the upper side 2nd extension part 5 is made to contact | abut to the rear surface of the seat frame 30. FIG.

  The depth of the recess 7 can be appropriately selected according to the foaming ratio of the foamed synthetic resin, the shape of the second extension 5, the thickness of the maximum bulge 5 a, etc., but from the maximum bulge 5 a to the recess 7. It is preferable that the height H to the bottom surface is 5 to 25 mm, particularly 10 to 20 mm. In addition, when setting a foaming ratio high, since the volume of the foaming synthetic resin at the time of filling a cavity space becomes large, it is preferable to set the said height H high. Thereby, in the metal mold | die 20, the cavity space above the convex part 25 for forming this recessed part 7 is fully ensured, and defects, such as a resin fracture, can be prevented.

  The basic configuration of the seat pad 1 is substantially the same as that of the upper second extending portion 5 except that the concave portion 7 constituting the easily deformable portion is provided on the surface facing the main body portion 3. This is the same as the seat pad 100A shown in FIGS.

  Next, the metal mold | die 20 for shape | molding the seat pad 1 is demonstrated. As shown in FIG. 2, in this embodiment, the mold 20 has an upper mold 21, a lower mold 22, and a middle mold 23 set on the upper mold 21. Also in this embodiment, the front surface side of the seat pad main body 2 is formed by the cavity surface of the lower die 22 and the seat pad main body 2 is formed by the cavity surfaces of the upper die 21 and the middle die 23 as in the mold 110A of FIG. The rear side is molded. Hereinafter, for convenience, the configuration of each part of the mold 20 will be described with the direction of each part of the mold 20 corresponding to the vertical direction, the left-right direction, and the front-rear direction of the seat pad body 2 (that is, the left-right direction in FIG. The configuration of each part of the mold 20 will be described in which the direction is the vertical direction, the lower side in FIG. 2 is the front, the upper side in FIG. 2 is the rear, and the direction perpendicular to the plane of FIG.

From the upper end surface and the left and right side surfaces of the middle mold 23, projecting portions 24 for forming the recesses 6 project. The protrusion 24 is formed continuously from the upper end surface of the middle mold 23 to the left and right side surfaces. The main body 3 of the seat pad body 2 is formed by the cavity space S ₁ between the cavity bottom surface of the lower mold 22 and the front 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 22. 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 rear surface of the protruding portion 24 and the cavity ceiling surface of the upper mold 21. . Cavity ceiling surface of the upper mold 21 that faces the cavity space S ₃ has a concave and a concave portion 21a in the separating direction from the rear surface of the projecting portion 24.

  The parting line 26 between the upper mold 21 and the lower mold 22 is located near the base end of the upper second extension 5, and the parting line 27 between the upper mold 21 and the middle mold 23 is the upper second 2 Located near the tip of the extension 5.

From the rear surface of the projecting portion 24 facing the cavity space S _3, the convex portion 25 for forming the recess 7 it is projected. In this embodiment, the convex part 25 consists of a convex line extended in the left-right direction. The outer surface of the convex portion 25, gradually rises from the rear surface of the projecting portion 24, and the distal end side has a curved surface curved convexly inwardly of the cavity S _1. The outer surface shape of the convex portion 25 substantially matches the inner surface shape of the concave portion 7, and the protruding height of the convex portion 25 from the rear surface of the protruding portion 24 is substantially equal to the depth of the concave portion 7. In addition, the width and the extended length of the convex portion 25 are substantially the same as the width and the extended length of the concave portion 7, respectively.

As will be described later, the convex portion 25 has a function of sufficiently filling the cavity ceiling surface of the upper mold 21 with the foamed synthetic resin raw material that expands in the cavity space S ₃ toward the distal end side of the upper second extending portion 5. Play. At that time, in order to flow uniformly toward the distal end side of the second upper extending portion 5 as a whole foamed synthetic resin raw material in the cavity space S _3, the projection of the convex portions 25 from the rear surface of the projecting portion 24 It is preferable that the height is constant from one end side to the other end side in the extending direction of the convex portion 25. In addition, the shape of the convex part 25 is not limited to this.

As FIG. 2, the leading end side region of the second upper extending portion 5 than the convex portion 25 of the rear surface of the projecting portion 24 facing the cavity space S ₃ is inclined so that high enough tip side ing. Moreover, the cavity ceiling surface of the upper mold 21 that faces the cavity space S ₃ (concave portion 21a) is also inclined so as a whole a high enough tip side of the second upper extending portion 5. Note that the parting line 27 of the front end side of the second upper extending portion 5 is desirably disposed at the highest position in the cavity S _3, slightly (for example, about 5 to 10 mm) than the lower It may be arranged at a position.

The basic structure of the die 20 is also, except that the projections 25 are provided on the rear surface of the projecting portion 24 facing the cavity space S _3, substantially, the mold 110A of FIG. 10 described above It is the same.

When manufacturing the seat pad 1 using the mold 20, first, the upper mold 21 and the lower mold 22 are opened, and the reinforcing material 10 is attached to the middle mold 23. At this time, the reinforcing material 10 is brought into close contact with the middle mold 23, and a portion of the reinforcing material 10 that overlaps the convex portion 25 has a shape protruding into the cavity space S ₃ along the outer surface of the convex portion 25.

Next, the foamed synthetic resin raw material is injected into the lower mold 22, the upper mold 21 and the lower mold 22 are clamped, and the foamed synthetic resin raw material is heated and foamed. This foamed synthetic resin raw material fills the cavity spaces S ₁ , S ₂ , S ₃ in this order. 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. Further, the reinforcing material 10 is integrated with these back surfaces (surfaces facing the inside of the recess 6 in the first extension portion 4 and the second extension portion 5).

Also in this die 20, similarly to the cavity S ₁₀₃ in the die 110A of FIG. 10 described above, the cavity space S _3, the upper second extending portion 5 from the rear surface of the main body portion 3 as the distal end side by the amount that is the separated shape, it has a rising gradient toward the tip end side of the upper second extending portion 5 as a whole, parting line 27 is disposed at a higher position within the cavity S ₃ Therefore, gas hardly remains in the concave portion 21a of the cavity ceiling surface, and the gas is discharged from the parting line 27 to the outside of the mold 20 relatively smoothly. As a result, formation defects such as voids in the upper second extending portion 3 are prevented.

In the the mold 20, synthetic resin foam material which expands in the cavity S ₃ is as Figure 2, rides over the projection 25 which protrudes into a cavity S ₃ from the rear surface of the projecting portion 24 upward It flows to the tip end side of the second extension portion 5. When getting over the convex portion 25, the flow of the foamed synthetic resin raw material is directed to the cavity ceiling surface of the upper mold 21. Thus, foamed synthetic resin material is now fully filled in the cavity space S ₃ to the cavity ceiling surface of the upper mold 21, the second upper extending portion 5, even more, molding defects such as voids are unlikely to occur Become.

After the foamed synthetic resin filling the cavity spaces S _{1 to} S ₃ is cured, the upper die 21 and the lower die 22 are opened to release the seat pad 1. Thereafter, a finishing operation such as deburring is performed as necessary to complete the seat pad 1.

  When the seat back portion 50 is configured using the seat pad 1, the seat pad 1 is attached to the seat frame 30, and the skin material 40 is attached to the outer surface of the seat pad 1. At this time, as shown in FIG. 3, first, the upper end portion and the left and right end portions of the seat frame 30 are respectively engaged with the recesses 6 on the upper rear side and the left and right sides of the seat pad 1 so that the front side of the seat frame 30 is engaged. The main body 3 of the seat pad 1 is disposed. Thereafter, the upper second extending portion 5 that has been raised rearward is bent forward and brought into contact with the rear surface of the seat frame 30. And the skin material 40 is made to adhere to the outer surface of the seat pad 1 in this state. The upper second extending portion 5 is restrained by the skin material 40 so as to be in contact with the rear surface of the seat frame 30. Thereby, the backrest part 50 is comprised.

  In the seat pad 1, a concave portion 7 is provided on the front surface of the upper second extending portion 5, and the concave portion 7 moves forward in the middle of the upper second extending portion 5 in the vertical direction. An easily deformable portion that is easily bent and deformed is formed. Thereby, after attaching the seat pad 1 to the seat frame 30, the upper second extension portion 5 can be bent and deformed relatively easily forward and brought into contact with the rear surface of the seat frame 30. In addition, since the upper second extending portion 5 is relatively weak in force to move away from the rear surface of the seat frame 30 and return to the original position, it is relatively easy to use a relatively low rigidity as the skin material 40. In addition, the upper second extended portion 5 can be maintained in contact with the rear surface of the seat frame 30. In addition, by providing the easily deformable portion in the upper second extending portion 5 in this way, the upper second extending portion 5 extends in the extending direction accompanying the forward bending deformation of the upper second extending portion 5. Since the easily deformable portion can absorb or suppress the extension of the upper second extended portion 5, the upper second extended portion 5 after the front second bent portion 5 is bent and deformed forward with a relatively high accuracy. The frame 30 can be disposed at a predetermined position on the rear surface.

  In particular, in this embodiment, the easily deformable portion is composed of a concave portion 7 provided on the front surface of the upper second extending portion 5, and when the upper second extending portion 5 is bent and deformed forward, Since the concave portion 7 is deformed so that the width in the extending direction of the upper second extending portion 5 is reduced, the upper second extending portion 5 extends along with the bending deformation of the upper second extending portion 5. The extension in the direction is absorbed by the deformation of the recess 7. Thereby, the arrangement | positioning precision of the front-end | tip part of this upper 2nd extension part 5 after making the upper side 2nd extension part 5 bend-deformed forward can be improved further.

<Other configuration of the concave portion constituting the easily deformable portion>
4 (a) and 4 (b) are cross-sectional views showing another example of the shape of the recess that constitutes the easily deformable portion, and FIG. 5 shows another example of the easily deformable portion using the recess. FIG.

In the above-described embodiment, the concave portion 7 has a so-called mountain-shaped cross-sectional shape in which the bottom surface is convexly convex toward the inner side of the upper second extending portion 5, but the cross-sectional shape of the concave portion constituting the easily deformable portion. Is not limited to this. For example, it may have a trapezoidal cross-sectional shape whose width becomes narrower toward the back side, as in the concave portion 7a in FIG. 4 (a), and has a width toward the back side, as in the concave portion 7b in FIG. 4 (b). It may be a triangular cross-sectional shape that narrows. The cross-sectional shape of the concave portion constituting the easily deformable portion may be a polygonal shape other than that illustrated. In addition, the trapezoidal cross-sectional shape is more preferable for the trapezoidal cross-sectional shape and the triangular cross-sectional shape. This is when the foamed synthetic resin to be gradually filled in the cavity space S ₃ proceeds toward the distal end side of the second upper extending portion 5, the cross-sectional shape of the convex portion 25 of the mold 20 to form a recess This is because the trapezoidal shape makes it difficult for the foamed synthetic resin to entrain air when it gets over the convex portion 25, and defects such as lack of thickness are less likely to occur. In this case, similarly to the concave portion 7 in the first embodiment, the corner portion where the upper side surface of the concave portion 7a and the front surface of the upper second extending portion 5 intersect, the lower side surface of the concave portion 7a and the upper second extended portion. The corner portion where the front surface of the protruding portion 5 intersects and the corner portion where the upper and lower side surfaces and the bottom surface of the concave portion 7a intersect each other are curved so that these surfaces are smoothly connected to each other (with R). It is preferable that With this configuration, the convex portion 25 of the mold 20 that forms the concave portion 7a also rises gently from the protruding portion 24 of the middle die 23 and has a rounded corner on the tip side. The probability of entraining air when getting over the convex portion 25 can be further reduced.

  In the above-described embodiment, only one (one strip) of the concave portion 7 constituting the easily deformable portion is provided on the front surface of the upper second extending portion 5, but as shown in FIG. Two (two) or more concave portions 7 may be provided at intervals in the extending direction of the extending portion 5. By comprising in this way, it becomes possible to make the upper side 2nd extension part 5 bend | flexibly or curvedly deform | transform more flexibly.

  Each of the above embodiments is an example of the present invention, and the present invention may be configured other than illustrated.

  For example, in the above-described embodiment, only the upper second extending portion 5 of the seat pad body 2 is raised backward, but the second extending portions 5 on both the left and right sides are also raised backward. It may be a different shape. The first extending portion 4 and the second extending portion 5 may also be provided on the lower side of the seat pad main body 2, and the lower second extending portion 5 may be shaped to be raised rearward.

  In the above embodiment, the recess 7 has a groove shape extending continuously in the width direction of the second extension portion 5, but the shape of the recess 7 is not limited to this. For example, a plurality of recesses 7 may be formed intermittently in a perforation shape in the width direction of the second extension portion 5.

  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.

1 Seat pad (foamed synthetic resin molding)
DESCRIPTION OF SYMBOLS 2 Seat pad main body 3 Main part 4 1st extension part 5 2nd extension part 6 Concave part 7 Concave part 10 Reinforcement material 20 Mold 21 Upper mold | type 22 Lower mold | type 23 Medium mold | type 24 Projection part 25 Convex part 30 Seat frame 40 Skin material

Claims (7)

The main part,
An extension part extending from the main part,
A foamed synthetic resin molded body in which the main body portion and the extending portion are integrally formed of the foamed synthetic resin by the expansion of the foamed synthetic resin from the main body portion toward the distal end side in the extending direction of the extending portion. Because
At the time of use of the foamed synthetic resin molded body, in the foamed synthetic resin molded body used by deforming the extending portion so that the tip side approaches the main body portion,
The extension part is provided with an easily deformable part , and faces the main part when the extension part is deformed so that its distal end approaches the main part of the outer surface of the extension part. A concave portion that is recessedly fitted on the inner side of the extending portion is provided on the surface on the side to be engaged (hereinafter referred to as a surface facing the main portion), and the thickness of the extending portion where the concave portion is located is 5 to 25 mm. A foamed synthetic resin molded body characterized in that the easily deformable portion is constituted by the concave portion . 2. The surface of the extension portion opposite to the main body portion in a direction away from the main body portion in a state in which the extension portion is deformed so that a tip side thereof approaches the main body portion. It is convexly curved, and the middle part of the extending part in the extending direction is the largest bulging part that bulges most away from the main body part,
At least a part of the easily deformable portion is at the same distance as the maximum bulging portion from the base end side in the extending direction of the extending portion toward the distal end side. . The foamed synthetic resin molded body according to claim 1 , wherein the concave portion has a groove shape extending in a direction orthogonal to the extending direction of the extending portion. 4. The cross-sectional shape of the recess in a direction parallel to the extension direction of the extension portion and in a direction orthogonal to the surface of the extension portion facing the main body according to claim 1 is wider toward the back side of the recess. A foamed synthetic resin molded product characterized in that the shape becomes narrower. The foamed synthetic resin molded body according to claim 4 , wherein the bottom surface of the concave portion is convexly curved toward the inner side of the extending portion. The foamed synthetic resin molded body according to claim 4 , wherein the cross-sectional shape of the recess is trapezoidal. The foamed synthetic resin molded body according to any one of claims 1 to 6 , wherein the foamed synthetic resin molded body is a seat pad.

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