JP6552453B2 - Vehicle seat pad and method of manufacturing the same - Google Patents

Description

  The present invention relates to a vehicle seat pad constituting a vehicle seat and a method of manufacturing the same.

  Conventionally, a seat pad constituting a seat or backrest of a vehicle seat such as an automobile has been conventionally made of a flexible polyurethane foam so as to obtain a comfortable cushioning property. However, in recent years, there has been a movement to promote weight reduction or reduce the amount of expensive urethane used, and an invention that responds to this has been proposed (for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 9-70330

  However, claim 1 of Patent Document 1 is “a layered different hardness pad of a vehicle seat comprising two upper and lower foam layers, wherein the upper layer is formed of polyurethane foam and the lower layer is polystyrene foam. Is formed, and the upper and lower layers are integrally joined. Layered Hardness Pad for Vehicle Seats ", there is a possibility that void or notch defects may occur during foam molding of polyurethane foam. There is. Usually, as shown in FIG. 16, after setting the polystyrene foam which is the lower layer LR to the upper mold K2, the mold is closed and then the polyurethane foam which is the upper layer UP is formed by foam molding. Loses its place to go. The polystyrene foam of the lower layer LR (the “core pad” of the present invention) is non-air-permeable, and the rising excess gas is accumulated on the lower surface of the lower layer LR to cause the insufficient thickness F in the polyurethane foam of the upper layer UP. . Moreover, since this lack of thinness can occur inside the product, there is a problem that it is difficult to find after foam molding. Furthermore, if the upper layer UP is to be molded integrally with the lower layer LR, it becomes a difficult and troublesome problem to disassemble the product.

  The present invention solves the above-mentioned problems, and even when using a non-air-permeable foam, weight reduction and urethane use are prevented so as not to cause a defect in thickness due to excess gas generated in foam molding of a soft urethane foam. It is an object of the present invention to provide a vehicle seat pad and a method of manufacturing the same for realizing a reduction in amount.

In order to achieve the above object, the gist of the invention according to claim 1 is a vehicle seat pad in which at least a contact surface portion on the side on which an occupant abuts is formed of a soft polyurethane foam, Then, a through hole penetrating from the front surface side to the back surface side is provided, a recess larger than the hole diameter of the through hole is provided on the back surface side, and a hole on the back surface side related to the through hole is arranged at the bottom of the recess. A core pad and a soft polyurethane foam, the contact surface portion is formed on the design surface side, and the through hole filled so as to fill the hollow including the through hole and the hole on the back surface side An upper layer pad that forms a filling portion and a hollow filling portion, and an inner surface side opposite to the design surface side is bonded to the surface of the core pad, and the non-breathing than the apparent density of the flexible polyurethane foam Foam look Only density Ri small der, the exposed surface of the recess filled portion, in the vehicle seat pad, wherein a recessed hole that is recessed into the depressions unfilled portion is formed. The subject matter according to claim 2 is a vehicle seat pad in which at least the contact surface portion on the side on which the occupant abuts is formed of a soft polyurethane foam, wherein the non-air-permeable foam is used. A core pad in which a through hole is provided and a recess larger than the hole diameter of the through hole is provided on the back side, and a hole on the back side related to the through hole is disposed in the bottom of the recess; Then, the contact surface portion is formed on the design surface side, and the through hole filling portion and the hollow filling portion filled so as to fill the inside of the hollow including the through hole and the hole on the back surface side are formed. On the other hand, the inner surface side opposite to the design surface side includes an upper layer pad joined to the surface of the core pad, and the apparent density of the non-breathable foam is smaller than the apparent density of the soft polyurethane foam. Oh is, the sympathizers Are recesses formed on the back surface of the soil lying on the vehicle seat pad, wherein the recess the the concave bottom of the recess is formed. The subject matter according to claim 3 is a vehicle seat pad in which at least a contact surface portion on the side on which an occupant abuts is formed of a soft polyurethane foam, wherein the non-air-permeable foam is used. A core pad in which a through hole is provided and a recess larger than the hole diameter of the through hole is provided on the back side, and a hole on the back side related to the through hole is disposed in the bottom of the recess; Then, the contact surface portion is formed on the design surface side, and the through hole filling portion and the hollow filling portion filled so as to fill the inside of the hollow including the through hole and the hole on the back surface side are formed. On the other hand, the inner surface side opposite to the design surface side includes an upper layer pad joined to the surface of the core pad, and the apparent density of the non-breathable foam is smaller than the apparent density of the soft polyurethane foam. Oh is, the recess In the vehicle seat pad, wherein the annular groove is formed between the side walls forming a recess wherein the Hama portion. The vehicle seat pad of the invention according to claim 4 is characterized in that, in claim 1, an annular groove is formed between the depression filling portion and the side wall forming the depression. The vehicle seat pad of the invention according to claim 5 is characterized in that, in claim 1, a recess is formed on the back surface of the core pad, and the recess is formed on the recessed bottom of the recess. A vehicle seat pad according to a sixth aspect of the present invention is the vehicle seat pad according to the first to fifth aspects, wherein the core pad is provided with a recess that gently falls toward the back surface and is lowered, and the bottom of the recess has the transparent base. It is characterized in that a hole on the surface side related to the hole is disposed. The vehicle seat pad of the invention according to claim 7 is characterized in that, in claims 1 to 6, the non-air-permeable foam of the core pad is a molded product of foamed polypropylene or foamed polystyrene.
The gist of claim 8 is a method for manufacturing a vehicle seat pad in which at least a contact surface portion on the side where an occupant abuts is formed of a soft polyurethane foam, and the apparent density is smaller than that of the soft polyurethane foam. A non-air-permeable foam is provided with a through-hole penetrating from the surface side to the back side, and a recess larger than the hole diameter of the through-hole is provided on the back side, and A core pad provided with a hole on the side, the back side is in contact with the upper mold surface, and a depression hole is formed in the upper mold surface, and the depression hole of the depression is formed in the hole hole of the depression hole The core pad is set on the upper mold surface so as to face each other, then a raw material for soft polyurethane foam is injected onto the lower mold surface and the mold is closed, and then the contact surface on the design surface side Forming a portion, and The inside of the dent including the hole on the back side is filled to form a through hole filling part and a dent filling part, and the inner surface side is foam-molded with an upper layer pad of a soft polyurethane foam bonded to the surface of the core pad. There exists in the manufacturing method of the vehicle seat pad characterized by the above-mentioned. A method of manufacturing a vehicle seat pad according to a ninth aspect of the present invention is the method according to the eighth aspect, further comprising providing a projecting portion at the bottom of the hole of the recessed hole, and between the projecting portion and the side wall of the recess The core pad is set on the upper mold surface so that a gap remains between the bottom portion and the bottom of the recess. According to a tenth aspect of the present invention, there is provided a vehicle seat pad manufacturing method according to the eighth or ninth aspect, wherein the non-breathable foam of the core pad is made of a foamed polypropylene or a foamed polystyrene, and further on the surface of the core pad to the back side. It is characterized in that a depression is provided so as to be gently lowered and lowered, and a hole on the surface side related to the through hole is disposed in the concave bottom area of the depression.

  The vehicle seat pad of the present invention and the method for producing the same comprise a non-air-permeable foam having an apparent surface density smaller than the apparent density of the flexible polyurethane foam while forming the contact surface portion with the upper layer pad of the flexible polyurethane foam. By providing a through hole and a recess in the constructed core pad, a defect in thickness due to an excess gas generated in foam molding of a soft urethane foam is eliminated, and an anchor effect can be obtained by forming a through hole filling portion and a hollow filling portion. Since the integration of the upper pad and the core pad is strengthened, it not only enables comfort and weight reduction such as cushioning, but also exhibits excellent effects in yield improvement and quality improvement.

It is explanatory drawing sectional drawing which sets a core pad to the foaming type | mold in the mold open state used for the manufacturing method by the form of the seat pad of this invention, and inject | pours a foaming raw material. It is the elements on larger scale which set a core pad to the upper type | mold of FIG. FIG. 2 is an explanatory cross-sectional view in which the mold is closed after injection of the foam material of FIG. 1; It is explanatory drawing which foam-molded the upper layer pad with a core pad. It is an expanded sectional view which a foaming raw material raises the inside of a through-hole in a foaming molding process. It is an expanded sectional view around a hollow of FIG. It is an explanatory sectional view of a seat pad after demolding. It is the perspective view which looked at the seat pad of FIG. 7 from the back surface side. It is the perspective view which looked at the seat pad of FIG. 7 from the surface side. FIG. 6 is an enlarged cross-sectional view for reference instead of FIG. 5. It is an expanded sectional view around a hollow concerning a seat pad of a reference which replaces FIG. FIG. 6 is an enlarged cross-sectional view of another embodiment replacing FIG. 5; FIG. 7 is an enlarged cross-sectional view around a recess according to another seat pad in place of FIG. 6; FIG. 6 is an enlarged cross-sectional view of a second alternative to FIG. 5; FIG. 7 is an enlarged cross-sectional view around a recess according to a seat pad of a second alternative embodiment instead of FIG. 6. It is an explanatory large sectional view of prior art.

Hereinafter, a vehicle seat pad according to the present invention (hereinafter also simply referred to as “seat pad”) and a manufacturing method thereof will be described in detail. 1 to 15 show an embodiment of the seat pad of the present invention and the method of manufacturing the same, and FIG. 1 is a cross-sectional view of setting the core pad to the foam mold in the mold open state and injecting the foam material. Fig. 3 is a cross-sectional view with the die closed, Fig. 4 is a cross-sectional view of the upper layer pad with the core pad formed by foam molding, and Fig. 5 is a foaming raw material in the through-hole during the foam molding process. 6 is a cross-sectional view around the recess of FIG. 4, FIG. 7 is a cross-sectional view of the seat pad after demolding, FIG. 8 is a perspective view of the seat pad as viewed from the back side, and FIG. 10 is a cross-sectional view of the reference in place of FIG. 5, FIG. 11 is a cross-sectional view around the recess of the seat pad of the reference in place of FIG. FIG. 13 is a cross-sectional view around a recess of a seat pad according to another embodiment instead of FIG. 6, and FIG. 14 is FIG. Second alternative embodiment of a cross-sectional view of Waru, FIG. 15 is a cross-sectional view around the recess of the seat pad of the second alternative embodiment in place of FIG.
Each figure is simplified for easy understanding of the drawings, and portions not directly related to the present invention are omitted. The core pad eliminates the cross-section hatching.

(1) Method of Manufacturing Vehicle Seat Pad In the method of manufacturing a vehicle seat pad, at least the contact surface portion 41 on the side where the occupant abuts is made of a soft polyurethane foam, and the foam of the upper layer pad 4 of the soft polyurethane foam is formed. It is a manufacturing method in which the inner surface 4b side is joined to the lightweight core pad 2 by molding. The seat pad P is used as a seat or back of a vehicle seat. Here, the present invention is applied to a seat cushion pad for a driver's seat as shown in FIGS. Prior to foam molding of the upper layer pad 4, the core pad 2 and the foaming mold 7 are prepared.

The core pad 2 is a bulk non-air-permeable foam. 7 is a core member that is made of a non-breathable foam having an apparent density smaller than the apparent density of the soft polyurethane foam forming the upper layer pad 4 and is disposed on the back side of the cushion pad P as shown in FIG. The density comparison between the core pad 2 and the upper layer pad 4 is based not on the density of the material before foaming but on the apparent density after foaming.
Prior to foam molding of the upper layer pad 4, the core pad 2 which has been foam-formed in advance is provided with a through hole 23 penetrating from the surface 2a side to the back surface 2b side, and further, the back surface 2b side is larger than the hole diameter of the through hole 23 A recess 24 is provided (FIG. 2). Moreover, the core pad 2 is provided with a recess 25 which is gradually lowered toward the back surface 2b on the front surface 2a and is lowered, and the concave bottom area 251 of the recess 25 is the hole 23a on the surface 2a side related to the through hole 23 Distribute. And the hole 23b by the side of the back surface 2b which concerns on the through-hole 23 is arranged in the bottom part 241 of the hollow 24 dented in a mortar shape. Here, the "front side" and the "back side" of the core pad 2 are literally the "front side" of the paper surface and the "back side" of the paper surface in the cushion pad P of FIG. . The “design side” and “inner side” of the upper layer pad 4 are also “front side” on the paper surface and “back side” on the paper surface, in the cushion pad P of FIG. is there. The word is used properly to make it easy to identify the part.

The non-breathable foam constituting the core pad 2 is sufficient if its apparent density is smaller than the apparent density of the soft polyurethane foam forming the upper layer pad 4, but a non-breathable foamed polypropylene or foamed polystyrene molded body is sufficient. More preferable. For example, a molded polystyrene foam made of beaded polystyrene is a non-breathable foam with air bubbles sealed inside, and the bulk of the volume is made of gas and light weight, and its apparent density is the appearance of a flexible polyurethane foam. It can be smaller than the density. The foamed polypropylene of the bead method foamed polypropylene is also very similar to the foamed polystyrene, and it is functionally excellent as the material of the core pad 2 by making a non-breathable foam with air bubbles sealed inside, and the apparent density can be reduced. The core pad 2 of the present embodiment also uses foamed polypropylene. Foamed polypropylene is more elastic than foamed polystyrene, and is more preferable as a constituent material of the core pad 2 for the seat pad P.
Reference numeral 28 denotes an upper end surface of a protruding portion that protrudes horizontally outward in the middle of the outer wall of the core pad 2 when the core pad 2 is set in the foam type 7. Reference numeral 29 denotes an opening provided in the core pad 22. Reference numeral 291 denotes a large diameter portion disposed on the back side, reference numeral 292 denotes a small diameter portion, and reference numeral 293 denotes a receiving surface. When the core pad 22 is set on the upper die 9 as shown in FIG. 1, a space is secured between the receiving surface 293 and the upper die surface 91.

  The foam mold 7 is a split mold as shown in FIG. 1, and the lower mold 8 and the upper mold 9 are connected by a hinge 71 so as to be able to open and close. When the mold 71 is closed as shown in FIG. 3 with the hinge 71 as the fulcrum, the whole is in the form of a bowl and the entire lower mold surface 81 forming the design surface 4a of the contact surface portion 41 and the one having the dent in the center are slightly convex. Then, the cavity C of the cushion pad P is formed by the upper mold surface 91 matched with the back surface 2b of the core pad 2. A depression 92 is formed in the upper mold surface 91, and the set of the core pads 2 on the upper mold surface 91 is such that the depression 240 of the depression 24 faces the hole 920 of the depression 92 (see FIG. 2). If the hole port 920 is larger than the recess port 240, it becomes easier to take in excess gas, which is more preferable. In the present embodiment, a protruding portion 93 is provided on the hole bottom 921 of the recessed hole 92. At the hole bottom 921, a stick-like projecting portion 93 is formed in a rod shape. When the core pad 2 is set on the upper mold surface 91 (FIGS. 1 and 5), between the protrusion 93 and the side wall 242 of the recess 24, and between the protrusion 93 and the bottom 241 of the recess 24. The projecting portion 93 is formed so as to secure a gap ε therebetween. The foam mold 7 shown in FIGS. 1 to 6 has a structure in which the upper layer pad 4 with the core pad 2 having the cushion pad P is formed in a manner reverse to the cushion pad P of FIG. It has become.

Using the foaming mold 7 and the core pad 2, the seat pad P is manufactured as follows, for example.
First, the foam mold 7 is brought into the mold open state of FIG. Under this mold open state, the back surface 2b side of the core pad 2 is in contact with the upper mold surface 91, and the core pad 2 is placed so that the recess port 240 of the recess 24 faces the hole 920 of the recessed hole 92. Set on the mold surface 91 (FIG. 2). In the present embodiment, the projection 93 is provided such that a gap ε remains between the projection 93 and the side wall 242 of the recess 24 and between the projection 93 and the bottom 241 of the recess 24. The core pad 2 is set on the upper mold surface 91.
After the core pad 2 is set on the upper mold surface 91, the injection nozzle NL or the like is used on the lower mold surface 81 indented like a bowl, and the upper layer pad 4 is formed using the foam material g (raw material for flexible polyurethane foam) Inject a predetermined amount.

  Subsequently, the upper mold 9 is operated to close the mold (FIG. 3). When the upper mold 9 and the lower mold 8 are closed, a cavity C for the cushion pad P in which the core pad 2 is insert-set is formed. Although the mold is closed after the injection of the foam material g in this embodiment, the foam material g may be injected after the mold is closed.

  After closing the mold, the process proceeds to foam molding in the main step. The upper layer pad 4 made of a soft polyurethane foam having a contact surface portion 41 (here, “seat surface portion”) of the seated occupant on the design surface 4a side is foam-molded. The mold closed state of FIG. 3 is maintained for a predetermined time, and the upper layer pad 4 with core pad 2 in which the inner surface 4b side opposite to the design surface 4a of the upper layer pad 4 is joined to the surface 2a of the core pad 2 is formed.

In the foaming process of the upper layer pad 4, after rising so as to fill the cavity C for the upper layer pad 4 main body having the contact surface portion 41 on the side on which the occupant abuts, as shown in FIG. Advances inward (Fig. 5). Here, since the liquid foam raw material g has a large resistance due to the constricted portion of the through hole 23 immediately before reaching the recess 24, the foaming raw material g starts to be foamed and hardened. Reaching the hole 23 b on the back surface 2 b side of the through hole 23, the curing of the foam raw material g is finished in the recess 24. Further, a protrusion 93 is further provided in the hole bottom 921 so that a space ε remains between the protrusion 93 and the side wall 242 of the recess 24 and between the protrusion 93 and the bottom 241 of the recess 24. When the core pad 2 is set on the upper mold surface 91, it is extremely difficult for the foaming raw material g to reach the core pad back surface 2b beyond the recess 24. Foam cure. Thus, the contact surface portion 41 is formed on the design surface 4a side, and the hollow 24 including the through hole 23 and the hole 23b on the back surface 2b side is filled to form the through hole filling portion 43 and the hollow filling portion 44. The upper layer pad 4 of the soft polyurethane foam whose side is bonded to the surface 2a of the core pad 2 is foam-molded (FIGS. 4 and 6).
On the other hand, surplus gas (including residual gas present in the mold) generated in the foam molding of the upper layer pad 4 has a low airflow resistance of the through-hole 23 unlike the liquid foam raw material g. Exit smoothly (arrow in Fig. 5). Before the foaming raw material g rises and reaches the through hole 23, most of the surplus gas reaches the recess 24 through the through hole 23. Moreover, since the dent 25 that gently falls toward the back surface 2b side and is lowered is provided on the core pad surface 2a, surplus foaming gas is collected at an early stage of foam molding to the concave bottom region 251 of the dent 25. Head. Since the concave bottom area 251 has the hole 23 a on the surface 2 a side of the through hole 23, the excess gas passes through the through hole 23 quickly and is stored in the recess 24. When the recessed hole 92 is provided in the upper mold 9, surplus gas can be stored in the recessed hole 92. Excess gas does not exist in the joining area between the core pad 2 and the upper layer pad 4, and the conventional lacking defect F is solved.

  By the way, even if the upper layer pad 4 of soft polyurethane foam is foam-molded, it has poor adhesion with non-air-permeable foams such as foamed polypropylene and expanded polystyrene constituting the core pad 2, and as it is, integration of both is not possible. It is enough. However, according to the present invention, in the foam molding of the upper layer pad 4, the through hole filling portion 43 and the hollow filling portion 44 filled in the through holes 23 of the core pad 2 exert an anchor effect, and the upper layer pad 4 and the non-air-permeable foam Integrate with the core pad 2. Furthermore, in the present embodiment, as shown in FIG. 1, the core pad 2 is formed with the opening 29 with the receiving surface 293, and the overhanging portion where the upper end surface 28 becomes substantially horizontal at the time of setting. Support integration. At the time of foam molding of the upper layer pad 4, the foam material g descends the small diameter portion 292 of the opening 29, and the foam material g infiltrates into the receiving surface 293 on the large diameter portion 291 side to foam and harden. The exposed portion 43 to be filled is received by the receiving surface 293 so that the core pad 2 and the upper layer pad 4 are integrated. Further, in the foam molding of the upper layer pad 4, the upper layer pad 4 rides on the protruding upper end surface 28 of the core pad 2 as shown in FIG. .

After the foam molding of the upper layer pad 4 is completed and the mold is removed, a desired cushion pad P in which the core pad 2 and the upper layer pad 4 with no missing portion F are integrated is obtained (FIG. 8 and FIG. 9).
Reference numeral 441 denotes an exposed surface formed by the forefront of the foaming raw material g appearing in the recess 24, and reference numeral 442 denotes a recess in which the protruding end portion 933 of the projecting portion 93 that forms a gap ε with the recess side wall 242 is left on the exposed surface 441. It is a hole. The reference numeral 4A indicates a main portion, 4B indicates a side portion, 4C indicates a mating portion with the backrest, 49 indicates a hanging groove, 491 indicates a vertical groove, and 492 indicates a horizontal groove.

FIGS. 10 and 11 show a method of manufacturing a reference seat pad in place of FIGS. 5 and 6. 10 and 11 do not have the recessed hole 92 and the protrusion 93 present in the upper mold 9 of FIGS. Nevertheless, in the foaming process of the upper layer pad 4, the excess gas can be stored in the recess 24 through the through hole 23 as shown in FIG. 10, and the excess gas is not left in the bonding area between the core pad 2 and the upper layer pad 4 . The upper layer pad 4 including the contact surface portion 41 is formed by foaming the upper layer pad 4 by providing a larger recess 24 compared to the hole diameter of the through hole 23 on the back surface 2b side of the core pad 2 as in FIGS. In addition to the main body, the through hole filling portion 43 and the hollow filling portion 44 are formed (FIG. 11). Excess gas generated in the foam molding is guided to the upper half of the depression 24 through the through hole 23.
12 and 13 show another method for manufacturing a seat pad in place of FIGS. 5 and 6. In the core pad 2, a columnar recess 26 is formed on the back surface 2 b, and a columnar recess 24 is formed on the concave bottom 261 of the recess 26. A depression 92 and a projection 93 are provided on the upper mold surface 91 facing the recess 24 in the same manner as in FIG. 5, but a cylindrical projection 95 is formed on the periphery of the depression 92. When the core pad 2 is set on the upper mold surface 91 such that the core pad back surface 2 b side is in contact with the upper mold surface 91, the tip of the protruding portion 95 is in contact with the concave bottom 261. Therefore, in the foam molding process, the foam material g does not end only in the recess 24 through the through holes 23, and the cured product of the foam material g is retained in the recess 26 even if it rises. In the foam molding of the upper layer pad 4, similarly to FIGS. 1 to 7, in addition to the main body of the upper layer pad 4 including the contact surface portion 41, the through hole filling portion 43 and the hollow filling portion 44 are formed (FIG. 13). Excess gas generated in the foam molding is guided to the recess 24 and the recessed hole 92 through the through hole 23.
14 and 15 show a method for manufacturing a seat pad according to a second alternative embodiment instead of FIGS. 5 and 6. The size of the recess 24 is enlarged to the size of the recess 26 in FIG. 13 and the recess 26 is eliminated. A columnar recess 24 larger than the hole diameter of the through hole 23 is provided on the back surface 2 b side of the core pad 2, and the depressed hole 92, the projecting portion 93, and the cylindrical raised portion 95 are formed on the upper mold surface 91 as in FIG. 12. Form. When the core pad 2 is set on the upper mold surface 91 so that the core pad back surface 2b side is in contact with the upper mold surface 91, the tip of the raised portion 95 is in contact with the hollow bottom portion 241 and the tip of the protrusion 93 is Enters the through hole 23. In the foam molding of the upper layer pad 4, similarly to FIGS. 1 to 7, in addition to the main body of the upper layer pad 4 including the contact surface portion 41, the through hole filling portion 43 and the hollow filling portion 44 are formed (FIG. 15). An annular groove R is formed between the recess filling portion 44 and the side wall 242 of the core pad 2 forming the recess 24 by the tip of the raised portion 95 abutting on the recess bottom portion 241. Excess gas generated in the foam molding is guided to the recess 24 and the recessed hole 92 through the through hole 23.
The other configuration is the same as the description of the method of manufacturing the seat pad in FIGS. 1 to 9, and the description is omitted. 1 to 7 indicate the same or corresponding parts.

(2) Seat pad The seat pad P (here, “cushion pad”) obtained by the above-described manufacturing method of FIGS. 1 to 9 has at least a contact surface portion 41 on the side where an occupant contacts with a soft polyurethane foam. The seat pad P includes the core pad 2 and the upper layer pad 4.

  The core pad 2 is made of a non-air-permeable foam, and is provided with a through hole 23 penetrating from the surface 2a side to the back surface 2b side. Further, a recess 24 having a larger diameter than the diameter of the through hole 23 is provided on the back surface 2 b side, and the bottom 23 1 of the recess 24 is provided with the hole 23 b on the back surface 2 b side related to the through hole 23. The depression 24 may be a mortar-shaped depression 24 shown in FIGS. 1 to 7 or a columnar depression 24 as shown in FIG. A recess 25 is provided on the surface 2a of the core pad 2 so as to be gently lowered and lowered toward the back surface 2b, and the recess 23 of the recess 25 has a hole 23a on the surface 2a side related to the through hole 23 It is arranged.

Alternatively, the core pad 2 may be formed as shown in FIG. 13 in which the recess 26 is formed on the back surface 2 b and the recess 24 is formed on the concave bottom 261 of the recess 26. If the recess 26 is provided, even if the foaming raw material g that has entered the recess 24 overflows due to foam molding of the upper layer pad 4, the foamed raw material g is accumulated in the recess 26. It does not spread and stain on the back of P.
The non-breathable foam of the core pad 2 is more preferably a foamed polypropylene or polystyrene foam as described above. Low-cost compared to flexible polyurethane foam, molded foam of polystyrene foam and polystyrene foam as closed cells and most of the volume of gas is lightweight, airtight and shape-retaining, and can maintain moderate shape retention This is convenient for the necessary core pad 2.

The upper layer pad 4 was made of a soft polyurethane foam, and a contact surface portion 41 was formed on the design surface 4a side, and the upper pad 4 was filled so as to fill the inside of the depression 24 including the through hole 23 and the hole 23b on the back surface 2b side. The through hole filling portion 43 and the hollow filling portion 44 are formed. The inner surface 4b side opposite to the design surface 4a side is a foamed molded body joined to the surface 2a of the core pad 2. Even though the flexible polyurethane foam has the through hole filling portion 43 in which the through holes 23 are filled, the anchor effect is exhibited, but the hollow filling portion 44 in which the hollow 24 larger than the hole diameter of the through hole 23 is filled is present. The anchor effect is further strengthened.
Further, as shown in FIG. 6, FIG. 13, and FIG. 15, when a concave hole 442 that is recessed into the hollow filling portion 44 is formed on the exposed surface 441 of the hollow filling portion 44, the upper pad 4 is foam-molded. The passing resistance of the foam material g at the concave hole portion can be made large by the protuberance 93, which is more preferable. While allowing the surplus foaming gas to pass, the passage of the foaming raw material g is suppressed and the inflow into the recess 24 is reduced. Furthermore, in the seat pad P of the second alternative embodiment shown in FIG. 15, an annular groove R is provided between the recess filling portion 44 and the side wall 242 forming the recess 24 to provide a more preferable cushion pad P ( Details later).

Then, the apparent density of the non-breathable foam forming the core pad 2 is set to be smaller than the apparent density of the soft polyurethane foam forming the upper layer pad 4 of the upper layer pad 4, and the desired density shown in FIGS. The seat pad P is completed. If such a seat pad P is covered with an unillustrated skin, a seat cushion for the vehicle seat is completed.
The other configuration is the same as the configuration described in (1) Seatpad manufacturing method, and the description thereof is omitted. The same reference numerals as those described in (1) indicate the same or corresponding parts.

(3) Effects The vehicle seat pad configured as described above and the method for manufacturing the same include the core pad 2 and the upper layer pad 4, and the core pad 2 has a smaller apparent density than the apparent density of the soft polyurethane foam. Because it is made of breathable foam, weight reduction proceeds. Nevertheless, since the contact surface portion 41 with the seated occupant is provided on the design surface 4a side of the upper layer pad 4 made of a soft polyurethane foam, comfort such as cushioning is ensured.

  And if the through-hole 23 which penetrates from the surface 2a side of the core pad 2 to the back surface 2b side is provided, the core pad 2 is set in the upper mold 9 and the upper layer pad 4 is foamed as shown in FIGS. However, the surplus gas generated in the foam molding process escapes to the core pad back surface 2b side through the through hole 23, so that the shortage defect shown in FIG. 16 can be suppressed. When the core pad 2 is provided with the recess 24 larger than the hole diameter of the through hole 23 on the back surface 2 b side and the hole 23 b on the back surface 2 b side related to the through hole 23 is disposed in the bottom portion 241 of the recess 24 (FIG. 10, FIG. 11) The foaming raw material g that has passed through the through holes 23 together with the surplus gas is cured in the recess 24 (FIG. 11), so that the core pad back surface 2b is not soiled.

  Further, the through hole 23 and the recess 24 are provided, and the upper layer pad 4 is foamed and formed into a soft polyurethane foam, and the contact surface portion 41 is formed on the design surface 4a side, and the holes on the through hole 23 and the back surface 2b side When the through hole filling portion 43 and the hollow filling portion 44 filled so as to fill the hollow 24 including the opening 23 b are formed, the through hole filling portion 43 and the hollow filling portion 44 exert an anchor effect to form the upper layer pad 4 and the like. Promote integration of core pad 2 integrally. Since the dent 24 larger than the hole diameter of the through hole 23 is formed, if the dent filling portion 44 exists, this serves as a stopper to further increase the bonding force between the upper layer pad 4 and the core pad 2.

Furthermore, a recess 25 is provided on the surface 2a of the core pad 2 so as to be gently lowered and lowered toward the back surface 2b, and the hole 23a on the surface 2a side related to the through hole 23 is arranged in the recessed bottom area 251 of the recess 25. Then, excess foaming gas generated by foaming of the upper layer pad 4 in FIG. 3 quickly moves to the concave bottom region 251 through the recess 25 and goes to the through hole 23 and the recess 24. It is possible to almost eliminate the defect in meat that can be made into 4.
In addition, a depression 92 is formed in the upper mold surface 91, and the core pad 2 is set on the upper mold surface 91 so that the depression 240 of the depression 24 faces the hole 920 of the depression 92. Since the surplus foaming gas can be stored in the depression hole 92 together with the recess 24 with surplus power, the surplus gas in the joining region between the core pad 2 and the upper layer pad 4 can be removed, and the conventional lacking defect can be solved all at once. In addition, the excess gas accumulated in the recess 24 and the recessed hole 92 is slightly increased in pressure, and it is possible to suppress the escape of gas necessary for foam molding out of the mold and to promote good foam molding. .

Further, when a concave hole 442 that is recessed into the hollow filling portion 44 is formed on the exposed surface 441 of the hollow filling portion 44 (FIG. 6), the foam raw material g at the concave hole portion is formed by foam molding of the upper layer pad 4. Therefore, it is possible to suppress the inflow of the foaming raw material g into the recess 24 while allowing the surplus gas to pass therethrough. Even if the recess 24 is not so large, it is possible to avoid the foam raw material g from overflowing the recess 24 and contaminating the core pad back surface 2b. The exposed surface 441 of the dent 24 and the dent filling portion 44 can be reduced, and the appearance of the core pad back surface 2b is improved.
Further, when the recess 26 as shown in FIG. 13 is formed in the core pad back surface 2 b and the recess 24 is formed in the recessed bottom 261 of the recess 26, the foam material g from the recess 24 is formed by foam molding of the upper layer pad 4. Even if it overflows, since it accumulates in the recess 26, the hardened portion of the foam material g does not spread on the back surface of the cushion pad P and become dirty.
Further, as shown in FIG. 15, when the annular groove R is formed between the recess filling portion 44 and the side wall 242 forming the recess 24, the hardened portion of the foam material g spreads on the back surface of the cushion pad P You can shut out By foam molding of the upper layer pad 4, the tip of the cylindrical raised portion 95 can be brought into contact with the hollow bottom portion 241 and the outer wall of the cylindrical raised portion 95 can be brought into close contact with or close to the hollow sidewall 242 as shown in FIG. This is because it is almost impossible for the foaming raw material g to pass through this close contact or proximity region without being cured and to come out of the depression 24. In addition, when the outer diameter of the cylindrical raised portion 95 is set to be slightly larger than that of the recess 24, it can also serve as an attachment portion when setting the core pad 2 to the upper die 91.
As described above, the vehicle seat pad and the manufacturing method thereof are extremely useful because they exhibit the various excellent effects described above.

  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. Shape, size, number, material of core pad 2, through hole 23, recess 24, recess 25, recess 26, upper layer pad 4, through hole filling portion 43, recess filling portion 44, recess hole 442, annular groove R etc. Etc. can be appropriately selected according to the application. Although the embodiment uses the cushion pad P for the seat, it can also be applied to a back pad for the backrest.

2 core pad 2a surface (core pad surface)
2b Back side (core pad back side)
23 Through-hole 24 Depression 25 Depression 26 Depression 4 Upper layer pad 4a Design surface (upper layer pad design surface)
4b Inner surface (upper pad inner surface)
DESCRIPTION OF REFERENCE NUMERALS 41 contact surface portion 43 through hole filling portion 44 hollow portion 441 exposed surface 442 recessed hole 81 lower mold surface 91 upper mold surface 92 recessed hole 93 protrusion P seat pad (cushion pad)
R annular groove ε gap

Claims (10)

A vehicle seat pad in which at least a contact surface portion on a side where an occupant abuts is formed of a soft polyurethane foam,
A non-air-permeable foam is provided with a through-hole penetrating from the surface side to the back side, and a recess larger than the hole diameter of the through-hole is provided on the back side, and A core pad with a side hole,
A flexible polyurethane foam is formed, and the contact surface portion is formed on the design surface side, and the through hole filling portion and the dent filling are filled so as to fill the inside of the dent including the through hole and the hole on the back surface side. An upper layer pad whose inner surface side opposite to the design surface side is bonded to the surface of the core pad, and has an apparent density of the non-breathable foam than the apparent density of the flexible polyurethane foam density is small der is,
A vehicular seat pad, wherein a concave hole recessed into the hollow filling portion is formed on an exposed surface of the hollow filling portion . A vehicle seat pad in which at least a contact surface portion on a side where an occupant abuts is formed of a soft polyurethane foam,
A non-air-permeable foam is provided with a through-hole penetrating from the surface side to the back side, and a recess larger than the hole diameter of the through-hole is provided on the back side, and A core pad with a side hole,
A flexible polyurethane foam is formed, and the contact surface portion is formed on the design surface side, and the through hole filling portion and the dent filling are filled so as to fill the inside of the dent including the through hole and the hole on the back surface side. An upper layer pad whose inner surface side opposite to the design surface side is bonded to the surface of the core pad, and has an apparent density of the non-breathable foam than the apparent density of the flexible polyurethane foam density is small der is,
A vehicular seat pad , wherein a recess is formed in a back surface of the core pad, and the recess is formed in a recess bottom of the recess . A vehicle seat pad in which at least a contact surface portion on a side where an occupant abuts is formed of a soft polyurethane foam,
A non-air-permeable foam is provided with a through-hole penetrating from the surface side to the back side, and a recess larger than the hole diameter of the through-hole is provided on the back side, and A core pad with a side hole,
A flexible polyurethane foam, wherein the contact surface portion is formed on the design surface side, and the through-hole filling portion and the hollow filling are filled so as to fill the hollow including the through-hole and the rear side hole. An upper layer pad whose inner surface side opposite to the design surface side is bonded to the surface of the core pad, and has an apparent density of the non-breathable foam than the apparent density of the flexible polyurethane foam density is small der is,
An annular groove is formed between the recess filling portion and the side wall forming the recess . The vehicle seat pad according to claim 1 , wherein an annular groove is formed between the recess filling portion and a side wall forming the recess. The vehicle seat pad according to claim 1 , wherein a recess is formed in a back surface of the core pad, and the recess is formed in a recess bottom of the recess. The surface of the core pad is provided with a recess that gently falls toward the back surface side and becomes lower, and a hole on the front surface side of the through hole is disposed in a bottom area of the recess . the vehicle seat pad according to any one. The vehicle seat pad according to any one of claims 1 to 6, wherein the non-air-permeable foam of the core pad is a molded article of foamed polypropylene or foamed polystyrene. A method for manufacturing a vehicle seat pad in which at least a contact surface portion on a side where an occupant abuts is formed of a soft polyurethane foam,
A non-breathable foam having an apparent density smaller than that of the flexible polyurethane foam, provided with a through hole penetrating from the front surface side to the back surface side, and further provided a recess larger than the hole diameter of the through hole on the back surface side. A core pad having a hole on the back surface side associated with the through hole at the bottom of the recess, the back surface side being in contact with the upper mold surface, and a recessed hole is formed in the upper mold surface; The core pad is set on the upper mold surface so that the recess opening of the recess faces the hole opening of the depression hole,
Next, the raw material for the flexible polyurethane foam is injected onto the lower mold surface and the mold is closed,
Thereafter, the contact surface portion is formed on the design surface side, and the recess including the through hole and the hole on the back surface side is filled to form a through hole filling portion and a recess filling portion, and the inner surface side is the above A method of manufacturing a vehicle seat pad, wherein an upper layer pad of a soft polyurethane foam bonded to a surface of a core pad is foam-molded. The core is further provided with a protuberance at the bottom of the hole of the recess, leaving a gap between the protuberance and the side wall of the recess and between the protuberance and the bottom of the recess. The method for manufacturing a vehicle seat pad according to claim 8, wherein the pad is set on the upper mold surface. The non-breathable foam of the core pad is a foamed polypropylene or polystyrene molded body, and a recess is formed on the surface of the core pad that gently falls toward the back side to be lowered. The manufacturing method of the vehicle seat pad of Claim 8 or 9 which has provided the hole side of the surface side which concerns on a hole.

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