JP6047363B2 - Seat back pad and manufacturing method thereof - Google Patents

Description

  The present invention relates to a seat back pad used in automobiles and the like, and a method of manufacturing the seat back pad.

  In general, a back pad used as a cushioning material in a backrest portion of a vehicle seat is made of a molded product of foamed resin such as flexible polyurethane foam, and is assembled to a metal frame and covered with a skin material. And it is comprised as a backrest part of the vehicle seat. Such a seat back pad has an inward projecting structure comprising a connecting portion extending rearward from the upper side of the pad main body and a flange portion extending downward from the connecting portion with a distance from the rear surface of the pad main body. The part is provided integrally and has a bag shape opened on the back surface, and the frame is held between the pad main body and the overhanging part.

  In order to foam-mold the back pad, a pad body corresponding to the surface side of the back pad and a lower mold for molding the outer surface of the connecting portion, a core mold for molding the inner surface of the pad body and the overhanging portion, and a core A three-part type mold is used, in which the mold is provided integrally and the upper mold that can be closed with respect to the lower mold by rotating around the hinge. In foam molding, a foamed resin stock solution is injected into the lower mold, and the upper mold is closed to the lower mold together with the core mold to perform foam molding. At that time, air accumulation easily occurs on the outer surface of the corner portion formed by the connecting portion and the flange portion. Therefore, a parting line between the lower mold and the upper die is arranged at this corner portion, and the accumulated air is parted. Exhausting from the line to the outside. After the molding, when the upper mold is rotated with respect to the lower mold around the hinge, the core mold and the molded back pad are rotated integrally with the upper mold so that the mold is opened. It has become.

  By the way, in the back pad, in order to attach a headrest made of another member, a through hole is formed that penetrates the connecting portion up and down, and in order to hide the mounting bracket of the headrest attached to the through hole, An annular protrusion that protrudes toward the bottom may be formed.

  However, in the mold for molding the back pad in which the annular protrusion is formed in the connecting portion, when the parting line is arranged at the corner between the connecting portion and the flange portion, the annular protrusion provided in the back pad is When the mold is opened, it will be located outside the pivot path of the upper mold and the mold cannot be opened. Therefore, a parting line must be arranged at the top of the annular protrusion. If it does so, the air collected in the corner part of a connecting part and a flange part cannot be exhausted outside, but molding defects, such as a lack of thickness, are carried out on the outer surface of the corner part of a connecting part and a flange part of a formed back pad. There is a problem that it is likely to occur.

JP 2009-220359 A

  The present invention has been made in view of the above points, and in a connecting portion extending rearward from the upper side of the pad main body, the through hole and the peripheral portion of the through hole are provided upward while ensuring formability. It aims at providing the back pad for sheets which can provide the annular protrusion which protrudes, and its manufacturing method.

The seat back pad according to the present invention includes a pad body made of a flexible foam, a connecting portion extending rearward from the upper side of the pad main body, and a back surface of the pad main body and spaced from the connecting portion. In a back pad for a sheet, in which a flange portion, a through-hole penetrating up and down the connecting portion, and an annular protrusion protruding upward at a peripheral edge portion of the through-hole are integrally foam-molded with a molding die In addition, a concave portion is provided at a boundary between the inner surface of the connecting portion and the inner surface of the flange portion so as to sink upward so as to make the connecting portion thin .

In addition, the manufacturing method of the seat back pad according to the present invention includes a pad main body made of flexible foam, a connecting portion extending rearward from the upper side of the pad main body, and a back surface of the pad main body. Forming a seat back pad comprising a flange portion extending downward from the connecting portion, a through-hole penetrating the connecting portion up and down, and an annular protrusion protruding upward from a peripheral portion of the through-hole In the method of manufacturing a back pad for a sheet that is foam-molded with a mold, the molding die includes a lower mold that molds the pad body and the outer surface of the connecting portion, an upper mold that molds the outer surface of the flange portion, and the connecting portion. And a core mold that molds the inner surface of the flange portion, a mold surface that molds the outer surface of the connecting portion in the lower mold, and a mold surface that molds the inner surface of the connecting portion in the core mold. The through hole A columnar part to be molded, an annular recess provided around the columnar part on the mold surface of the lower mold and the mold surface of the upper mold, and an inner surface of the connecting part in the core mold; The corner portion of the core mold forming the boundary with the inner surface of the flange portion is provided with a convex portion projecting in a direction in which the columnar portion projects from one surface of the core mold, and the foamed resin stock solution is applied to the lower mold. A sheet back pad is formed by pouring and closing the upper mold with respect to the lower mold.

  According to the present invention, the connecting portion extending rearward from the upper side portion of the pad main body can be provided with a through hole and an annular protrusion projecting upward at the peripheral portion of the through hole while ensuring formability. it can.

It is a front view of the back pad for sheets concerning one embodiment of the present invention. FIG. 2 is a rear view of the seat back pad shown in FIG. 1. FIG. 2 is a top view of the seat back pad shown in FIG. 1. It is the sectional view on the AA line of FIG. It is sectional drawing of the foaming mold which shape | molds the sheet | seat back pad shown in FIG. It is sectional drawing to which the principal part of FIG. 5 was expanded. It is the BB sectional view taken on the line of FIG.

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

  The back pad 10 of the embodiment shown in FIGS. 1 to 4 is a pad used as a cushion material in a backrest portion of a rear seat of an automobile, for example. The back pad 10 includes a pad main body 12 made of a flexible foam such as a flexible polyurethane foam, and a reinforcing cloth 14 laminated and integrated on the back side thereof, and woven or knitted fabric or leather is sewn together. The surface is covered with a skin material (not shown) and assembled to the frame 4 (see FIG. 4) to constitute a backrest portion.

  An inward flange-like overhanging portion 16 including a connecting portion 18 and a flange portion 20 is integrally provided on the upper side portion on the back side of the pad main body 12, and the frame 4 is provided between the pad main body 12 and the overhanging portion 16. Arranged.

  The connecting portion 18 extends from the pad main body 12 so as to protrude rearward Z, constitutes the upper portion of the back pad 10, and is provided with a plurality of (four in this example) through holes 32 spaced in the width direction W. It has been. The through hole 32 is for inserting a mounting bracket 28a provided in the headrest 28, and is provided so as to penetrate the connecting portion 18 up and down. In addition, an annular protrusion 34 that protrudes upward X from the upper surface of the connecting portion 18 is provided on the peripheral edge of the through hole 32 so as to surround the through hole 32.

  The flange portion 20 extends from the rear end portion of the connecting portion 18 downward X2 with a predetermined distance from the back surface of the pad main body 12, and has a bag shape that opens to the back surface together with the pad main body 12. At the boundary between the inner surface of the connecting portion 18 and the inner surface of the flange portion 20, that is, inside the corner portion 19 where the connecting portion 18 and the flange portion 20 are joined, outward (toward the outside of the corner portion 19) and more Specifically, a concave portion 21 that is depressed in the upper X1 is provided so that the connecting portion 18 is thin.

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

  As shown in FIG. 5, the foam mold 50 for molding the back pad 10 includes a lower mold 52 that molds the outer surfaces of the pad main body 12 and the connecting portion 18, and an upper mold 54 that molds the outer surface of the flange portion 20. And a core die 56 for molding the inner surfaces of the connecting portion 18 and the flange portion 20.

  The upper die 54 is provided so as to be rotatable with respect to the lower die 52 via a hinge 58, and is configured to open and close the upper surface opening of the lower die 52. The upper die 54 rotates upward p1 with respect to the lower die 52. Then, the upper surface opening of the lower mold 52 is opened, and when the lower mold 52 is rotated downward p2, the upper surface opening of the lower mold 52 is closed.

  The core mold 56 is disposed below the upper mold 54. When the upper mold 54 closes the upper surface opening of the lower mold 52, a cavity corresponding to the shape of the back pad 10 to be molded is formed between the lower mold 52 and the upper mold 54. 59 is formed. The core die 56 is detachably provided from the upper die 54 by a driving device 60 provided on the upper die 54.

  As shown in FIGS. 5 to 7, the foaming mold 50 is provided with a columnar portion 62 and an annular recess 64 for forming the through hole 32 and the annular protrusion 34 in the connecting portion 18 of the back pad 10. A convex portion 66 for forming the concave portion 21 is provided inside the corner portion 19 of the connecting portion 18 and the flange portion 20.

  Specifically, as shown in FIGS. 6 and 7, the columnar portion 62 protrudes from the mold surface 52 a that molds the outer surface of the connecting portion 18 in the lower mold 52 toward the core mold 56 that faces the mold surface 52 a. A first protrusion 68 that protrudes from a mold surface 56a that molds the inner surface of the connecting portion 18 in the core mold 56 toward a mold surface 52a of the lower mold 52 that faces the mold surface 56a, and It is comprised by matching. The annular recess 64 is recessed from the mold surface 52 a of the lower mold 52 toward the outside of the cavity 59 so as to surround the first protrusion 68.

  In such a mold provided with the annular recess 64, the bottom of the annular recess 64 passes through a locus indicated by a symbol L in FIG. 6 when the upper mold 54 rotates upward p1 about the hinge 58. , The position farthest from the hinge 58 is moved. Therefore, as shown in FIG. 7, the parting line PL of the lower mold 52 and the upper mold 54 is provided at the bottom of the annular recess 64 at the position where the annular recess 64 is provided, and at the other positions, the back pad 10 The parting line PL is provided in the location which shape | molds the corner | angular part 19 which the connection part 18 and the flange part 20 join.

  The convex portion 66 is formed outwardly on the corner portion 56c of the core die 56 where the die surface 56a for molding the inner surface of the connecting portion 18 and the die surface 56b for molding the inner surface of the flange portion 20 in the core die 56 are joined. More specifically, the second protrusion 70 is provided so as to protrude in the direction q protruding from the mold surface 56 a of the core mold 56. Thereby, the space | interval of the type | mold surface 56a of the core type | mold 56 and the type | mold surface of the lower mold | type 52 or the upper mold | type 54 which opposes this in the protrusion direction q of the 2nd protrusion 70 is narrowed.

  In order to manufacture the back pad 10 using such a foam molding die 50, first, the reinforcing cloth 14 previously sewn in a bag shape is placed on the core die 56 and fixed by a pin (not shown) or the like. .

  Next, after the foamed resin stock solution 80 is injected into the lower mold 52 using an injection device (not shown), the upper mold 54 and the core mold 56 are closed with respect to the lower mold 52 as shown in FIG. As a result, the foamed resin stock solution 80 fills the cavity 59 of the foam molding die 50 while foaming.

  Specifically, the foamed resin stock solution 80 injected into the lower mold 52 is moved from the side of the pad main body 12 formed between the lower mold 52 and the core mold 56 toward the upper side p1 (the tip of the core mold 56 ( That is, it flows so as to wrap around the mold surface 56 a) of the core mold 56.

  At this time, as shown in FIG. 6, the corner portion 56 c of the core mold 56 is provided with a convex portion 66 projecting in the projecting direction q of the second projecting portion 70. The foamed resin that flows toward the front portion of the flange portion 20 flows around the corner portion 56c by detouring so as to be pushed out in the protruding direction q by colliding with the convex portion 66.

  Then, the foamed resin that flows between the lower mold 52 and the core mold 56 flows into the flange portion 20 side between the upper mold 54 and the core mold 56 to mold the back pad 10.

  After foaming the back pad 10 in this way, the upper die 54 is opened, and the core die 56 is detached from the upper die 54 by the driving device 60, and then the back pad 10 is removed, thereby connecting the connecting portion. Thus, the back pad 10 having the concave portion 21 that is recessed in the upper X1 inside the corner portion 19 where the flange 18 and the flange portion 20 are joined is obtained.

  In the present embodiment as described above, the convex portion 66 that projects in the projecting direction q of the second projecting portion 70 is provided at the corner portion 56c of the core mold 56, so that the pad main body 12 side is directed upward p1. The foamed resin flowing in this way collides with the convex portion 66 and is pushed out in the protruding direction q, so that the liquid around the corner portion 19 of the back pad 10 is improved. Therefore, even if the parting line PL of the lower mold 52 and the upper mold 54 is not arranged at the corner 19, molding defects such as lack of wall are hardly generated on the outer surface of the corner 19 of the back pad 10.

  Further, in the present embodiment, since the recess 21 is provided inside the back pad 10, it does not affect the finished appearance of the sheet, and the flange portion 20 can be easily pulled out backward from the recess 21. Thus, the assembling work for assembling the back pad 10 to the frame 4 is easy.

  Moreover, although the example of the backrest part in a rear seat was demonstrated in the said embodiment, this invention is applicable also to the back pad used for the backrest part of a Freon seat. Although not enumerated one by one, various modifications can be made without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 10 ... Back pad 12 ... Pad main body 14 ... Reinforcement cloth 16 ... Overhang part 18 ... Connection part 19 ... Corner | angular part 20 ... Flange part 21 ... Recessed part 28 ... Headrest 28a ... Mounting bracket 32 ... Through-hole 34 ... Annular protrusion 50 ... Foaming Mold 52 ... Lower mold 54 ... Upper mold 56 ... Core mold 56c ... Corner 58 ... Hinge 59 ... Cavity 60 ... Drive device 62 ... Columnar portion 64 ... Annular recess 66 ... Projection 68 ... First projection 70 ... Second protrusion 80 ... Foamed resin stock solution

Claims (2)

A pad body made of a flexible foam; a connecting part extending rearward from the upper side of the pad main body; a flange part extending downward from the connecting part spaced apart from the back surface of the pad main body; In the back pad for a sheet, in which a through hole penetrating up and down the connecting portion and an annular protrusion protruding upward at the peripheral edge portion of the through hole are integrally molded with a molding die,
A seat back pad, comprising: a recess that is depressed upward so as to make the connecting portion thin at a boundary between an inner surface of the connecting portion and an inner surface of the flange portion. A pad body made of a flexible foam; a connecting part extending rearward from the upper side of the pad main body; a flange part extending downward from the connecting part spaced apart from the back surface of the pad main body; In the manufacturing method of the sheet back pad, the sheet back pad including the through hole penetrating the connecting portion up and down and the annular protrusion protruding upward at the peripheral edge portion of the through hole with a molding die,
The molding die includes a lower mold that molds the outer surface of the pad main body and the connecting part, an upper mold that molds the outer surface of the flange part, a core mold that molds the inner surface of the connecting part and the flange part, A columnar part that is provided between a mold surface that molds the outer surface of the connecting part in the lower mold and a mold surface that molds the inner surface of the connecting part in the core mold; Forming the boundary between the inner surface of the connecting portion and the inner surface of the flange portion in the core mold, and the annular recess formed around the columnar portion on the mold surface and the upper mold surface and forming the annular protrusion A convex portion that protrudes in a direction in which the columnar portion protrudes from one side of the core shape at a corner portion of the core shape ;
A method for producing a seat back pad, comprising: injecting a foamed resin stock solution into the lower die, and closing the upper die with respect to the lower die to form a seat back pad.

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