JP5925368B2 - Method for manufacturing vehicle seat pad - Google Patents

Description

  The present invention relates to a method for manufacturing a vehicle seat pad constituting a vehicle seat.

There is a seat cushion that constitutes a seat portion and a backrest of a seat that is mounted on a vehicle such as an automobile. A seat pad such as a flexible polyurethane foam is a main component, but there are cases where the seat pad bends and rubs against the seat frame when an occupant is seated, and sometimes generates abnormal noise.
For these reasons, in recent years, a seat pad has been proposed in which a cloth-like material such as a nonwoven fabric is adhered and integrated on the back side of the pad body and measures against abnormal noise are taken (for example, Patent Documents 1 and 2). ).

JP-A-9-11249 JP-A-2-145308

Patent Document 1 states, as in the claims, “the upper end and the lower die having an upper urethane foam space, and the felt terminal set along the upper urethane foam space wall in a convex shape. A rib parallel to the protruding portion is formed outside the protruding portion projecting on the upper mold side so as to be held, and a groove is provided between the outside of the protruding portion and the rib. The end of the felt is inserted into the urethane foam.
In addition, as described in the claims of Patent Document 2, “supporter material (“ cloth-like material ”in the present invention”) is formed larger than the bottom portion of the pad material, and the ends of the supporter material are a lower mold and an upper mold. It is configured to be sandwiched between the mold matching portions.

However, hybrid cars that have appeared in recent years are quieter at lower speeds, and more noise countermeasures are required, and in high-end cars, there is a demand for quality improvement that does not cause abnormal noise even if you touch each part of the seat when moving up and down etc. Therefore, the invention of Patent Document 1 cannot be said to be perfect for such a request. The vehicle seat pad is attached to the seat frame, and the pad main body has a standing wall-shaped outer peripheral portion projecting along the outer periphery to the back surface side. There is a need to take countermeasures against abnormal noise between the back-side thickness surface of the outer peripheral portion and the seat frame, and the countermeasure configuration of only the inner wall surface of the outer peripheral portion as in Patent Document 1 has not been able to respond. Further, Patent Document 2 has a configuration in which the end of the supporter material is sandwiched between the mold-matching portions of the lower mold and the upper mold, so that the gas escape at the time of foam molding cannot be controlled, and the pad body is poorly molded. was there. There was a problem that the supporter material bites into the parting line part, and the foaming gas escapes more than necessary, which causes problems such as so-called bottom up.
Therefore, at present, the parting line PL is provided at the highest point 10 in each outer peripheral portion 1a of the pad body 1 which is foam-molded as shown in FIG. The cloth material 5 is set on the upper mold surface 7A, and the pad main body 1 is foam-molded, while 51 is kept at a position 5 to 10 mm away from the parting line PL. However, even if the cloth-like material 5 is set on the upper mold 7A, the cloth-like material 5 is present only at a distance of 5 mm to 10 mm from the parting line PL. 11, there was a problem that the rubbing sound with the seat frame or the like still occurred. Moreover, the foam raw material leak (urethane leak) was held in the whole pad main body outer peripheral part 1a at the time of foam molding.

  The present invention solves the above problem, and occurs not only on the back side of the main part and side part of the pad body, but also on the back side thickness surface connected to the standing wall-shaped outer peripheral part of the pad body and between the seat frame. It is an object of the present invention to provide a method for manufacturing a vehicle seat pad that prevents abnormal noises from occurring and further takes measures against leakage of foaming raw materials during foam molding.

In order to achieve the above object, the gist of the invention described in claim 1 is that after the cloth material (5) is set in the upper mold (7), the foaming raw material (9) is injected and the lower mold (8) is used. In a manufacturing method of a seat pad that foam-molds a pad body (1) in which the cloth-like material (5) is attached and integrated on the back surface (1R) after closing the mold, the pad body (1) has an outer periphery A standing wall-shaped outer peripheral part (1a) projecting to the back surface (1R) side is formed along the outermost wall surface (13) related to the outer peripheral part (1a) at the highest point (10) at the tip thereof. After bending, the back side thick surface (11) continues, bent at the inward bend (14) beyond it, and the inner standing wall (12) extends, and the upper mold (7) and lower mold The parting line (PL) position with (8) is the outer peripheral part (1a) of the foamed pad body (1), which is higher than its highest point (10) projecting to the back (1R) side. It is provided at the lower point and is connected to the cloth material set in the upper mold (7). Using a foaming mold (6) in which a degassing hole for foam gas (7g) is provided in the upper mold, (i) the cloth-like material (5) is separated from its outer peripheral edge (51) to the center of the cloth-like material ( A plurality of incisions (52) in a strip shape toward the outer wall (13) from the outer peripheral edge (51) of the cloth-like material (5) via the back-side thickness surface (11). The length of the bent part (14) and the length of the inner standing wall (12) are entered, and the cloth-like material (5) with the strip-shaped part (53) having a plurality of strip-shaped parts (53) is formed in advance. (B) The outer peripheral edge (51) of the cloth-like material (5 ) with the strip-like part (53) is the highest point (10) in the outer peripheral part (1a) of the pad body (1) to be foam-molded. ) And the first step of setting the cloth-like material (5) on the mold surface (7A) of the upper mold (7) so as to be disposed in front of the parting line (PL), (c) releasing a second step of closing injection and the type of foaming material (9), from (d) the excess foaming gas in the foam forming gas release hole (7 g) Te, in the manufacturing method of the vehicle seat pad, characterized in that it comprises a third step the fabric-like material (5) is to foam molding of the pad body (1) which is integrated deposition, the. Here, “the highest point of the outer peripheral portion of the pad body that is foam-molded and projecting to the back side” means the outer peripheral portion at each outer peripheral point under the cross-sectional state of the foam mold during foam molding. The top point of the outer vertical wall to be created.
According to a second aspect of the present invention, there is provided a vehicle seat pad manufacturing method according to the first aspect, wherein the uneven surface portion (15) is formed on the back side thickness surface (11), and the undulating portion relating to the foaming mold (6) at that location is formed. On the curved surface, the strip-shaped portions (53) made of the notches (52) are overlapped with each other or the adjacent strip-shaped portions (53) are opened, and the cloth-shaped material (5) with the strip-shaped portions (53) And the outer peripheral edge (51) of the cloth-like material (5) according to the first step is the outermost part (1a) of the pad body (1) to be foam-molded. The cloth material (5) with the strip-shaped part (53) on the mold surface (7A) of the upper mold (7) so as to be placed in front of the parting line (PL) over the high point (10) It is characterized by setting.

  The method for manufacturing a vehicle seat pad according to the present invention includes a pad including a back-side thickness surface where a cloth-like material is connected to the outer periphery of the pad body with respect to contact with a seat frame or the like disposed on the back side of the pad body. Since it is attached to the back of the main unit, there is no rubbing noise between the pad main body and the frame, etc., contributing to the prevention of abnormal noise, and surplus foaming raw material during foam molding can be concentrated in one place, making post-deburring easy This is extremely useful.

It is the perspective view which looked at the seat pad from the back side in one form of the manufacturing method of the seat pad for vehicles of the present invention. FIG. 2 is a cross-sectional view of a seat pad present in a mold after foam molding, as seen in the direction of arrows II-II in FIG. 1. (A) is the elements on larger scale of FIG. 2, (b) is a comparison explanatory drawing which replaces (a). FIG. 4 is a sectional view taken along the line IV-IV in FIG. 1 and showing a seat pad in the mold after foam molding. FIG. 5 is a cross-sectional view illustrating a comparison instead of FIG. 4. It is a top view of a cloth-like material. It is the elements on larger scale of FIG. It is explanatory sectional drawing which inject | pours a foaming raw material after setting a cloth-like material to an upper mold | type. It is explanatory sectional drawing closed mold. It is an expansion perspective view around the outer peripheral part of a seat pad. It is description of the other aspect which replaces FIG.

  Hereinafter, the manufacturing method of the vehicle seat pad which concerns on this invention is explained in full detail. 1 to 11 show an embodiment of a method for manufacturing a vehicle seat pad (hereinafter also simply referred to as “seat pad”) according to the present invention. FIG. 1 is a perspective view of the seat pad as seen from the back side, and FIG. Fig. 3 is a partially enlarged view of Fig. 2, (B) is a comparative explanation drawing instead of (A), and Fig. 4 is an IV-IV line arrow view of Fig. 1. FIG. 5, FIG. 5 is a cross-sectional view for explaining comparison with FIG. 4, FIG. 6 is a plan view of a cloth-like material, FIG. 7 is a partially enlarged view of FIG. FIG. 10 is an enlarged perspective view around the outer periphery of the seat pad, and FIG. 11 is an explanatory sectional view of another embodiment instead of FIG. In addition, in each figure, in order to make a cloth-like material easy to understand, the thickness is drawn large.

  The seat pad S is a back pad for a backrest or a cushion pad that receives and supports the lower body of a seated passenger. This embodiment is applied to a cushion pad as shown in FIG. If a cushion pad is covered with a skin to form a seat cushion, a vehicle seat is formed by a known backrest and a known headrest. The seat pad S is a pad on which the cloth material 5 is attached and integrated on the back surface 1R after the cloth material 5 is set on the upper mold 7 and then injected with the foaming raw material 9 and closed with the lower mold 8. The main body 1 is manufactured by foam molding. As shown in FIG. 2, the pad main body is roughly divided into a main part 2 that supports the occupant's buttocks and thighs, and a side part 3 that protrudes on both sides of the main part and supports the side parts of the buttocks and thighs. Reference numeral 1c denotes a recess formed on the back side of the side part, and reference numeral 1e denotes a longitudinal groove running in the vehicle front-rear direction at the boundary between the main part surface 2a and the side part surface 3a.

In this seat pad manufacturing method, the position of the parting line PL between the upper mold 7 and the lower mold 8 is the highest point 10 of the outer peripheral portion 1a of the pad body 1 to be foam-molded and projecting to the back surface 1R side. The foaming mold 6 provided at a lower point is used. Unlike the conventional method of FIG. 3 (b), the parting line PL is provided at a position below the highest point 10 of the pad body outer peripheral portion 1a projecting to the back surface 1R side as shown in FIG. This is because the outer peripheral edge 51 of the cloth-like material 5 is arranged beyond the highest point 10 to the outer vertical wall surface 13 side of the outer peripheral portion 1a.
In the present invention, the seat pad cavity CA is formed by closing the mold as shown in FIG. 9, and the seat pad S and the pad main body 1 are molded upside down. The pad main body 1 is formed with a standing wall-shaped outer peripheral portion 1a extending toward the back surface 1R along the outer periphery thereof (FIG. 2). After being bent from the outer vertical wall surface 13 related to the outer peripheral portion 1a at the highest point 10 at the tip thereof, the back surface-side thickness surface 11 continues, bent at the inward bending portion 14, and further becomes the inner vertical wall surface 12. (A in FIG. 3). The upper mold 7 is provided with a corner portion 70 that forms the highest point 10 protruding from the outer peripheral portion 1a toward the back surface 1R. The upper mold 7 includes a part 79 for forming the outer vertical wall surface from the joint part 79 of the parting line PL, and a mold for forming a rear surface side thick surface which is the rear surface mold surface 7b of the side section 3 through the part 75 and the corner 70. An upper mold surface 7A is formed which continues to the surface portion 71, the inner corner portion 74, the inner standing wall surface forming mold surface portion 72, the recess mold surface portion 78, and the back surface side mold surface 7a of the main portion 2. Reference numeral 60 in FIG. 8 indicates a depression for the overhanging portion 4 formed by a part 75 of the outer standing wall surface mold surface portion, the back surface thickness forming surface portion 71 and the inner standing wall surface forming surface portion 72. The lower mold 8 is formed with a remaining portion 83 of the outer vertical wall mold surface portion from the joint portion 89, and further has a surface side mold surface 8b of the side portion 3, a vertical groove mold surface 8c, and a surface side mold surface 8a of the main portion. It is formed.

The seat pad S is manufactured using the foaming mold 6 as follows.
First, a portion 510 of the outer peripheral edge 51 of the cloth-like material 5 is arranged on the upper mold surface 7A in front of the outer peripheral portion 1a of the pad body 1 to be foam-molded without exceeding the highest point 10 thereof. On the other hand, the outer peripheral edge 51 other than the part 510 related to the cloth-like material 5 is disposed so as to exceed the highest point 10 of the pad body outer peripheral portion 1a to be foam-molded and before the parting line PL, The cloth material 5 is set on the upper mold surface 7A (first step).
Here, all of the remaining outer peripheral edge 511 other than the portion 510 related to the cloth-like material 5 exceeds the highest point 10 in each outer peripheral portion 1a of the pad main body 1 to be foam-molded, and before the parting line PL. The cloth-like material 5 is set on the mold surface 7 </ b> A of the upper mold 7 as arranged. A portion 510 of the outer peripheral edge 51 related to the cloth-like material 5 is disposed near the inwardly bent portion 14 on the back surface 2b of the vehicle front side main portion 2 with which the thigh of the occupant abuts, for example (FIGS. 1 and 4). ). The part 510 is kept on the upper mold surface 7A in front of the pad body outer peripheral portion 1a without exceeding the highest point 10 by changing the parting line position around the part 510 (described later). This is because the surplus foaming gas at the time of foam molding is collected and the surplus foaming gas and the surplus foaming raw material are released from here. At the time of foam molding, surplus foaming gas collects in the portion 510 through a gap between the yarns constituting the cloth-like material 5. On the other hand, the outer peripheral edge 51 other than the portion 510 related to the cloth-like material 5 is arranged so as to exceed the highest point 10 in the outer peripheral portion 1a of the foamed pad body 1 and before the parting line PL. Thus, the cloth-like material 5 is set on the upper mold surface 7A by covering the back-side thickness surface 11 connected to the outer peripheral portion 1a via the highest point 10 with the cloth-like material 5, and This is to eliminate the rubbing sound between the pad main body 1 and the seat frame including 11. In addition, the width of the back surface side thickness surface 11 of the pad main body 1 is about 5 mm to 10 mm as shown in FIG.

In foam molding after mold closing, the vertical distance α from the highest point 10 of the outer peripheral portion 1a shown in FIG. 3 (a) to the parting line PL is in the range of 10 mm to 20 mm, and the outer peripheral edge 51 of the cloth-like material 5 (Excluding part 510) is arranged at an upper point in front of the parting line PL. In the set of the cloth-like material 5 on the upper die surface 7A, the upper edge of the cloth-like material 5 is arranged between the highest point 10 and the parting line PL by arranging the outer peripheral edge 51 of the cloth-like material 5. Allow some misalignment when setting. Even if the outer peripheral edge 51 of the cloth-like material 5 is set somewhat apart from the parting line PL, the back-side thickness surface 11 can be reliably covered. On the other hand, even when the cloth-like material 5 is slightly moved toward the parting line PL when the upper mold is set, the cloth-like material 5 does not bite into the parting line PL and the joints 79 and 89.
As shown in FIG. 5, the parting line PL is positioned below the highest point 10 that protrudes toward the back surface 1 </ b> R at each outer peripheral portion 1 a of the foamed pad body 1 as shown in FIG. 5. It is also possible to use a foaming mold 6 set to However, the surplus foaming gas that has reached the portion 510 through the cloth-like material 5 may not be able to escape cleanly from the joints 79 and 89 near the portion 510. Therefore, in the present invention, the position of the parting line PL is provided at a lower point than the highest point 10 projecting to the back surface 1R side in the outer peripheral portion 1a of the pad body 1 to be foam-molded, A foaming mold in which the parting line PL is positioned at the highest point 10 in one region of the outer peripheral portion 1a of the pad main body 1 is employed (FIG. 4). And the part 510 of the outer periphery 51 which concerns on the cloth-like material 5 applied to this one area | region of the outer peripheral part of the pad main body 1 is set so that it may not exceed the highest point 10 of the pad main body outer peripheral part 1a. Only the parting line PL around the part 510 of the cloth-like material 5 uses the foaming mold 6 in which the parting line position is the highest point 10 of the pad body outer peripheral portion 1a to be foam-molded, and the surplus at the time of foam-molding The foaming gas is discharged smoothly and positively.

  Here, the cloth-like material 5 is a cloth-like sheet material, and in this embodiment, a non-woven fabric that is made into a sheet shape by fixing or intertwining fibers by mechanical, chemical, thermal, etc. without weaving. To do. The outer peripheral portion of the cloth-like material 5 covers the back surface side thick surface 11 having the uneven portion 15 and the part of the outer standing wall surface, and covers the main portion back surface 2b and the side portion back surface 3b. . Further, a cloth-like material with a strip-like portion 53 having a plurality of strip-like portions 53 by making a plurality of cuts 52 in a strip shape from the outer peripheral edge 51 of the cloth-like material 5 corresponding to the uneven portion 15 toward the cloth-like material central portion 50. The cloth-like material 5 processed and formed in advance 5 is used.

Specifically, it covers almost the entire longitudinal direction (excluding a part 510) of the back-side thickness surface 11 and exceeds the highest point of the outer peripheral portion 1a and covers the outer vertical wall surface in front of the parting line PL, The cloth-like material 5 is cut into a size that can cover the back surface 1R side of the main body, and further provided with a cut 52 (FIGS. 6 and 10). The direction of the incision 52 is provided in the normal direction at the most protruding point at the outer peripheral edge 51 where the cloth-like material 5 swells corresponding to the convex part 17 (or the concave part 16) of the concave-convex part 15 as shown in FIG. (FIG. 7). A plurality of cuts 52 that are parallel to the normal direction cuts 52 are provided, and the cloth-like material 5 with the strip-like parts 53 having a plurality of strip-like parts 53 is provided.
The length L of the notch 52 is the outer peripheral edge 51 of the cloth-like material 5 placed on the outer vertical wall surface 13 in a state where the cloth-like material 5 with the strip-like portion 53 is attached and integrated to the outer peripheral portion 1a (FIG. 10). Therefore, it is preferable to set the length so as to pass through the flat region β of the back-side thickness surface 11 and beyond the rounding region R of the inward bent portion 14 and into the region α of the inner standing wall surface 12. When the cutting tip 52a reaches the region of the inner vertical wall surface 12, even when the outer peripheral edge 51 slightly deviates toward the die joining portion 79 when the cloth-like material 5 with the strip-like portion 53 is set on the foaming die 6, the strip This is because the rounded region R is covered with the shape portion 53 and finally the curved surface of the uneven portion 15 can be covered cleanly. In FIG. 6, reference numeral 56 is a hole for locking the cloth-like material 5 to the upper mold 7, reference numeral 58 is a nozzle opening, and reference numeral 59 is smoothly bent from the side portion back surface 3 b to the inner standing wall surface 42 of the outer peripheral portion 4. The slit F for making it possible and the code | symbol F show the rectangular ferrite sheet piece stuck and integrated on the cloth-like material.

In this first step, the cloth-like material 5 with the strip-like part 53 is used, and first, the cloth-like material center part 50 covers the center part of the upper mold surface 7A. Subsequently, the strip-shaped portions 53 formed by the cuts 52 are overlapped or opened between the strip-shaped portions 53, and the outer peripheral edge 51 other than the portion 510 related to the cloth-like material 5 is formed by foam molding of the pad body 1. The cloth-like material with the strip-like part is set on the mold surface 7A of the upper mold 7 so as to be disposed in front of the parting line PL beyond the highest point 10 in each outer peripheral part 1a. When there is an uneven portion 15 on the back-side thickness surface 11 connected to the outer peripheral portion 1a, adjacent strip-shaped portions 53 made of cuts 52 are overlapped or adjacent to each other on the corresponding undulating portion of the upper mold 7. A curved surface is formed by opening the gap, and the cloth-like material 5 with the strip-like portion 53 is set on the upper die 6.
Specifically, when the convex portion 17 of the concave-convex portion 15 is formed on the back surface-side thickness surface 11, the undulating portion of the foaming mold 6 at that location is dented, and a plurality of the strip-shaped portions 53 are overlapped. The strip-shaped portion 53 is applied to form a curved surface of the undulating portion. Since the cloth-like portion to be attached to the undulating portion is composed of a plurality of strip-like portions 53, it is easy to set the curved shape of the undulating portion. On the other hand, the undulating portion of the foaming mold 6 that forms the concave portion 16 of the concavo-convex portion 15 has a convex shape, and the curved surface is formed by a plurality of strip-shaped portions 53 so as to open between the strip-shaped portions 53. Since the portion corresponding to the undulating portion is composed of a plurality of non-woven fabric strip-like portions 53, the raised hairs of the cloth-like material 5 enter and entangle with the gap ε formed between the strip-like portions 53.

  Instead of the cloth-like material 5 with the strip-like portion 53, the outer peripheral edge 51 other than the portion 510 related to the cloth-like material 5 exceeds the highest point of the pad main body outer peripheral portion 1a and is on the upper mold surface 7A before the parting line. The cloth-like material that has been preformed into a three-dimensional shape by hot pressing or the like can also be used. However, with respect to the outer peripheral portion 1a having the uneven portion 15 on the back surface side thickness surface 11, the cloth-like material 5 with the strip-shaped portion 53 is easier to set on the upper mold 7 following the shape of the uneven portion, and foaming is performed. It is more preferable that the shape can be maintained until the molding is completed.

  In the first step, after the cloth-like material 5 is set on the upper die 7, the process proceeds to the second step and the third step in which the foaming raw material 9 is injected and the mold is closed. After injection of the foaming raw material 9 and mold closing, the pad main body 1 made of foam is foam-molded so that the cloth-like material 5 is integrally attached to the back surface 1R. In this embodiment, after setting the cloth-like material 5 with the strip-shaped portion 53 to the foaming mold 6, the injection hose N or the like is used on the mold surface 8A that forms the cavity CA of the lower mold 8 with the mold open. A predetermined amount of foaming raw material 9 such as a urethane foam stock solution for forming the pad main body 1 is injected (FIG. 8). Subsequently, the upper die 7 is operated to close the die, and the second step is completed (FIG. 9). By closing the upper die 7 and the lower die 8, the sheet pad S cavity CA into which the cloth-like material 5 with the strip-like portion 53 is inserted is formed. In addition, after setting the cloth-like material 5 to the foaming mold 6, the foaming raw material 9 is injected and then the mold is closed. However, after setting the cloth-like material 5 to the foaming mold 6, the mold is closed, and then the foaming raw material is set. 9 can also be injected.

After closing the mold, the process proceeds to foam molding of the pad body 1 (third step). The mold closed state of FIG. 9 is maintained for a predetermined time, and the pad body 1 is foam-molded so that the cloth-like material 5 is attached and integrated on the back surface 1R side as shown in FIGS.
In the third step of foam molding, surplus foaming gas and surplus foaming raw material are discharged from the part 510 side of the outer peripheral edge 51 of the cloth-like material 5, and the pad body 1 on which the cloth-like material 5 is integrally attached. Is molded. Excess foaming gas in the foam molding process will be described with reference to FIG. 4. The surplus foaming gas travels along the cloth-like material 5 set on the upper mold surface 7A in the direction of the portion 510 of the cloth-like material 5 on the left side of the figure. Released from nearby joints 79,89. Since the parting line position of the joint portion coincides with the highest point 10 in the pad body outer peripheral portion 1a that is foam-molded as described above, surplus foaming gas is smoothly discharged. When the foam molding of the pad main body 1 is finished and removed, the cloth-like material 5 is deposited and integrated on the back surface 1R of the pad main body 1, and the cloth is formed on the back-side thickness surface 11 connected to the outer peripheral portion 1a except for a part 510. A desired seat pad S in which the material 5 is deposited and integrated is obtained. 1 and 5, reference numeral 19 denotes an exposed portion of the pad body 1, and a state diagram is shown in which the cloth-like material 5 is not attached around a portion 510 of the back-side thickness surface 11. The thickness surface can also be set to cover the cloth-like material 5 as much as possible.
When the seat pad S is covered with an unillustrated skin, it becomes a seat cushion for a seat of a vehicle seat (FIG. 1).

In the present embodiment, the position of the parting line PL between the upper mold 7 and the lower mold 8 is lower than the highest point 10 projecting to the back surface 1R side at the outer peripheral portion 1a of the pad body 1 to be foam-molded. While being provided at the point, a foaming mold in which the position of the parting line PL is aligned with the highest point 10 is used only in one region of the outer peripheral portion 1a of the pad main body 1. Further, with respect to the outer peripheral edge 51 of the cloth-like material 5, a portion 510 of the outer peripheral edge 51 related to the cloth-like material 5 applied to the one region of the outer peripheral part of the pad main body 1 is the highest point of the pad main body outer peripheral part 1a. The outer peripheral edge 51 other than the portion 510 related to the cloth-like material 5 does not exceed 10, exceeds the highest point 10 in the outer peripheral portion 1a of the pad main body 1 to be foam-molded, and before the parting line PL. The configuration is arranged (first step). Instead, a configuration as shown in FIG. 11 may be used.

That is, a foaming gas vent hole 7g communicating with the cloth material 5 set in the upper mold 7 is provided in the upper mold 7 in advance, and in the first step, the outer peripheral edge 51 of the cloth material 5 is formed by foam molding. The cloth-like material 5 is set on the mold surface 7A of the upper mold 7 so that the outer peripheral portion 1a of the pad main body 1 is disposed in front of the parting line PL over the highest point 10 thereof. Here, as shown in FIG. 11, the position of the parting line PL between the upper mold 7 and the lower mold 8 is projected to the back surface 1R side at each outer peripheral portion 1a of the foamed pad body 1 over the entire area. It is set at a lower point than the highest point 10. This is because the surplus foaming gas and surplus foaming raw material at the time of foam molding can be released from the gas vent hole 7g provided in the upper mold without releasing from the joint portions 79 and 89.
In the third step, surplus foaming gas and surplus foaming raw material are discharged from the gas vent 7g by foam molding, and the pad body 1 to which the cloth-like material 5 is integrally attached is foam-molded. The surplus foaming gas in the foam molding process travels along the cloth-like material 5 set on the upper mold surface 7A in the direction in which the gas vent hole 7g exists and is smoothly discharged from the gas vent hole. Since the foaming gas is released from the degassing hole 7g, all the outer peripheral edges 511 related to the cloth-like material 5 are arranged so as to exceed the highest point 10 of the pad body outer peripheral portion 1a and before the parting line PL. Thus, the cloth-like material 5 can be set on the upper mold surface 7A. In FIG. 11, when foam molding of the pad main body 1 is finished and the mold is removed, the cloth-like material 5 is attached to the back surface 1R of the pad main body, and the cloth-like material 5 is applied to the entire area of the rear-side thickness surface 11 of the outer peripheral portion 1a. The desired seat pad S that is integrally deposited is obtained.

  According to the seat pad manufacturing method configured as described above, the position of the parting line PL is lower than the highest point 10 projecting toward the back surface 1R side at the outer peripheral portion 1a of the foamed pad body 1. Using the foaming mold 6 provided at the point, and the outer peripheral edge 51 of the cloth-like material 5 exceeds the highest point 10 in the outer peripheral portion 1a of the pad body 1 to be foam-molded, the mold surface 7A of the upper mold 7 Since the cloth-like material 5 is set, the pad main body back surface 1R is covered with the cloth-like material 5 including the back-side thickness surface 11 connected to the outer peripheral portion 1a. The cloth-like material 5 can be attached to the pad main body portion that comes into contact with the seat frame or the like, and the rubbing sound between the seat pad S and the frame can be eliminated. The problem that the back side thickness surface 11 and the seat frame have been rubbed due to running vibration or seating can be solved. Measures against abnormal noise between the back surface side thick surface 11 connected to the outer peripheral portion 1a and the seat frame will be perfect.

  Then, the outer peripheral edge 51 of the cloth-like material 5 is arranged so as to exceed the highest point 10 in the outer peripheral portion 1a of the pad main body 1 to be foam-molded and before the parting line PL. Is set on the upper mold 7, the cloth-like material 5 can be easily set on the upper mold 7. By setting the outer peripheral edge 51 of the cloth-like material 5 so as to be within the range of the symbol α in FIG. 3 (a), that is, the section from the highest point 10 of the upper mold 7 to the parting line PL point, Since the state covering the thickness surface 11 can be maintained, it is easy to set the cloth-like material on the upper mold 7, which leads to improved workability. Further, since the outer peripheral edge 51 of the cloth-like material 5 is arranged in front of the parting line and there is room for reaching the parting line point, the cloth-like material 5 is connected to the parting line PL and the joints 79 and 89. There is no inconvenience that the foaming gas escapes more than necessary when it is bitten and foamed.

On the other hand, the parting line PL is positioned on the outer peripheral portion 1a of the pad body 1 to be foam-molded, and the foaming mold 6 provided below the highest point 10 projecting to the back surface 1R side is used. Although there is a concern that excess foaming gas at the time of molding cannot be removed, since the cloth-like material 5 is present on the back surface 1R of the pad body 1, excess gas escapes through the cloth-like material. There is no loss. Since the upper mold 7 is provided with the gas vent hole 7g for foaming gas, the excess foam gas is smoothly vented during foam molding.
In addition, when the foaming mold 6 that matches the position of the parting line PL to the highest point 10 in one region of the outer peripheral portion 1a of the pad main body 1 is used instead of the gas vent hole, the foaming through the parting line The surplus foaming gas at the time of molding and the surplus foaming raw material can be discharged smoothly and positively. In addition, burr at the time of foam molding can be concentrated on the parting line PL and the joints 79 and 89 around the portion 510. Conventionally, burrs were generated all over the parting line all around the foam molding, and it was difficult to remove these burrs in post-processing. However, the party was limited to parting line PL around 510. Since the groin position is the highest point 10 of the pad main body outer peripheral portion 1a to be foam-molded, burrs are gathered at one place to facilitate deburring in post-processing.
Further, when the foaming mold 6 in which the foaming gas degassing holes 7g are provided in advance in the upper mold 7 is adopted, there is no restriction on the portion 510, and the entire outer peripheral edge 51 of the cloth-like material 5 is foam-molded. The outer peripheral portion 1a can be disposed over the highest point 10 and before the parting line PL. Accordingly, the cloth material 5 can be set on the mold surface portion of the pad main body back surface 1R including the entire back surface thickness surface 11, and the cloth material 5 can be applied to the entire pad main body 1 in contact with the seat frame or the like. This prevents the rubbing noise between the seat pad S and the frame.

  In addition, the cloth-like material 5 with the strip-shaped portion 53 is previously processed and formed, and the strip-shaped portions 53 are overlapped with each other, or the strip-shaped portions 53 are opened to form a curved surface. The upper die surface 7A is provided with a strip-like portion 53 so that the outer peripheral portion 1a of the pad main body 1 to be foamed is placed over the highest point 10 and before the parting line PL. When the material 5 is set, the cloth-like material 5 can be attached and integrated by forming a curved surface matching the uneven portion 15 also on the back side thick surface 11 having the uneven portion 15 connected to the outer peripheral portion 1a. Since the portion of the strip-shaped portion 53 in which a plurality of cuts 52 are formed is less rigid than the other portions, the followability to the upper mold surface 7A is improved by foam molding of the pad body 1. By providing a plurality of the cuts 52, the followability can be improved even for a complicated uneven shape. By providing the narrow strip-like portion 53, the stiffness (rigidity) of the strip-like portion 53 is weakened and the followability is improved, and the back side thickness is bent at the highest point 10 from the outer vertical wall surface 13 of the outer peripheral portion 1a. In addition to being applied to the surface 11, it is possible to ensure the integration of the attachment to the concavo-convex portion 15. This contributes to improving the quality of the seat pad in which the cloth material 5 is deposited and integrated on the pad main body back surface 1R.

  The present invention is not limited to those shown in the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, and the like of the pad main body 1, the outer peripheral portion 1a, the cloth-like material 5, the foaming mold 6, and the foaming raw material 9 can be appropriately selected according to the application. Although the embodiment is applied to a cushion pad, it can also be applied to a back pad for backrest.

DESCRIPTION OF SYMBOLS 1 Pad main body 1R Back surface 1a Outer peripheral part 10 The highest point 5 Cloth-like material 51 Outer peripheral edge 510 A part of outer peripheral edge 511 All remaining outer peripheral edges 52 Notches 53 Striped part 6 Foaming mold 7 Upper mold 7A Upper mold surface 7g Gas Hole 8 Lower mold 9 Foaming raw material PL Parting line

Claims (2)

After setting the cloth material (5) on the upper mold (7), after pouring the foaming raw material (9) and closing the mold with the lower mold (8), the cloth material (5) is placed on the back surface (1R). In the manufacturing method of the seat pad for foaming the pad main body (1) to be adhered and integrated,
The pad main body (1) has a standing wall-shaped outer peripheral portion (1a) projecting to the back surface (1R) side along the outer periphery, and the outer vertical wall surface (13) related to the outer peripheral portion (1a) is projected to the protruding end. After being bent at the highest point (10), the back side thick surface (11) continues, bent at the inward bend (14) beyond it, and the inner standing wall (12) extends,
Also, the position of the parting line (PL) between the upper mold (7) and the lower mold (8) is projected to the back surface (1R) side at the outer peripheral part (1a) of the foamed pad body (1). The foaming mold (7g) is provided in the upper mold at the lower point than the highest point (10), and the upper mold (7) is provided with a venting hole for foaming gas (7g) communicating with the cloth material ( 6)
(A) A cloth in which a plurality of slits (52) are formed on the outer standing wall (13) in a strip shape from the outer peripheral edge (51) to the cloth-like material central part (50) on the cloth-like material (5). Put in a length that goes from the outer peripheral edge (51) of the shaped material (5) to the inner standing wall surface (12) through the back side thick surface (11) and beyond the inner bent portion (14), Formed in advance on a cloth-like material (5) with a strip-like part (53) having a plurality of parts (53),
(B) The outer peripheral edge (51) of the cloth-like material (5 ) with the strip-like part (53) is the highest point (10) in the outer peripheral part (1a) of the pad main body (1) to be foam-molded. And the first step of setting the cloth-like material (5) on the mold surface (7A) of the upper mold (7) so as to be disposed in front of the parting line (PL),
(C) a second step of injecting the foaming raw material (9) and closing the mold;
(D) a third step of foaming and molding the pad body (1) on which the cloth-like material (5) is deposited and integrated by discharging excess foaming gas from the gas vent hole (7g) by foam molding; A method for manufacturing a vehicle seat pad, comprising: Concave and convex portions (15) are formed on the back-side thickness surface (11), and the strip-shaped portions (53) made of the cuts (52) are formed on the curved surface of the undulating portion related to the foaming mold (6) at that location. The cloth-like material according to the first step, wherein the cloth-like material (5) with the strip-like part (53) is curvedly formed by opening the overlapping or adjacent strip-like parts (53), and forming the curved surface. The outer peripheral edge (51) of (5) is arranged at the outer peripheral part (1a) of the pad main body (1) to be foam-molded, exceeding its highest point (10) and before the parting line (PL). The method for manufacturing a vehicle seat pad according to claim 1, wherein the cloth material (5) with the strip-shaped portion (53) is set on the mold surface (7A) of the upper mold (7).

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