JP6563754B2 - Seat pad and manufacturing method thereof - Google Patents

Description

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

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 used as a main component, but when the occupant is seated, the seat pad may bend and rub against the seat frame, and sometimes an abnormal noise may be generated or the pad body may be torn. Improvements have been made by attaching a backing material such as a nonwoven fabric to the back surface of the pad body of the seat pad, but it is difficult to arrange the backing material up to the wrinkles of the pad body. If it is going to adhere backing material to the back of the pad body, high accuracy is required for setting the backing material to the foaming mold. When the backing material mold set is brought close to the joint of the foam mold mating surface, if the backing material is sandwiched between the mold mating surfaces, gas will be lost during foam molding. Therefore, as the backing material, a material whose outer peripheral edge is slightly smaller than the outer peripheral edge of the back surface of the pad main body is exclusively used.
Further, in the cushion pad in which the seat pad Z constitutes the seat portion, as the vehicle rear side is approached as shown in FIG. 9, the overhang portion 232 of the side portion 23 may be lowered, and the seat by the overhang portion 232 Support for frame F has become difficult. As a result, as shown in FIG. 10 (a), the seat frame F arranged near the outer edge of the pad main body back surface 2b does not contact the backing material 3, but outwards in the vehicle width direction where the pad main body 2 of the seat pad is exposed. This causes a situation where it is placed on the pad exposed surface 29 as shown in FIG. The pad exposed surface 29 is rubbed to generate abnormal noise, and the peeling surface 28 is easily formed. Furthermore, since it directly hits the pad body 2, a crack CK is generated.
For these reasons, inventions for dealing with the above problems have been proposed (for example, Patent Documents 1 and 2).

JP 2005-95256 A JP 2012-228422 A

However, as disclosed in Patent Document 1, the patent document 1 folds the tongue piece portion protruding from the cushion pad to the non-tensioning surface side opposite to the tensioning surface with respect to the cushion pad, and the tongue piece of the first type. The invention remains only in the invention of “a cushion pad molding method” in which a foamed resin stock solution is foamed and molded in a cavity between the first mold and the second mold. Further, since the tongue piece is folded and attached to the mold surface of the first mold and foamed, the portion where the tongue piece is folded swells, and the foaming raw material at the time of foam molding easily enters from here. When the infiltrated foaming material foams and cures at the portion of the tongue piece on the back side of the seat pad, the generation of abnormal noise does not stop.
Moreover, although patent document 2 makes the area | region of the uneven | corrugated | grooved part near the wrinkles of a pad main body sticking a nonwoven fabric, the work of the nonwoven fabric set which is a backing material falls to a certain extent, and the operation | work is severe. In addition, this manufacturing method usually requires setting the strip-shaped portion of the nonwoven fabric on the upper mold surface, and the setting operation of the nonwoven fabric to the foaming mold is more difficult.

  The present invention solves the above-mentioned problem, does not require high accuracy in the work in foam molding, reduces the work load, prevents the generation of abnormal noise due to rubbing with the seat frame, etc. over a long period of time. It is an object of the present invention to provide a vehicle seat pad excellent in preventing the pad body from being torn and a method for manufacturing the same.

In order to achieve the above-mentioned object, the gist of the invention described in claim 1 is that in the manufacturing method of a seat pad of a vehicle seat, a sheet-like backing material that is attached to and integrated with the back surface of the pad body by foam molding. A tongue-backed backing material with a tongue extending outwardly at a part of the periphery so that, when the mold is open, the tongue is folded over with its root as a fold and hidden behind the backing. Then, after setting into one split mold, the pad main body is integrally foamed with the backing material with tongue pieces, then removed from the mold, and then the folded tongue pieces are raised to form the folded portion. A seat pad which is tilted from one area of the pad body to the other area side of the pad body beyond the parting line, and the tip of the tongue piece is locked to the pad body in the other area It is in the manufacturing method. According to a second aspect of the present invention, there is provided a seat pad manufacturing method according to the first aspect of the present invention, wherein a protrusion to which the bent portion of the tongue piece is applied is provided in one split mold, and the protrusion on the side facing the bent portion is provided. A wall surface is formed on a curved surface that slopes downward from the upper end of the protrusion toward the folded main body portion of the tongue piece set in the one split mold, and the folded portion is applied to the curved surface, The backing material with a tongue piece is set in one division type. According to a third aspect of the present invention, there is provided a seat pad manufacturing method according to the first or second aspect, wherein a stitched portion is formed at the bent portion where the backing material and the tongue piece are connected.
The gist of the invention described in claim 4 is a seat for a vehicle seat comprising: a pad main body made of a foam; and a sheet-like backing material that is integrally formed on the back surface by foam molding of the pad main body. In the pad, the periphery of the backing material is positioned closer to the center of the back surface of the pad body than the outer edge of the back surface of the pad body, and a margin is provided between the periphery of the backing material and the outer edge of the back surface of the pad body. A pad exposed surface is formed between the outer peripheral edge of the backing material and the outer peripheral edge of the back surface of the pad body, and a sheet-like tongue piece extends outwardly at a part of the peripheral edge of the backing material. and sutured made or separate tongues Te Katazuki tongue made by extending outward backing material is formed, the tongue piece, one of said pad body located in the pad body rear surface side of the base Pa from regions beyond the party Grinding caused by mold face of the lower mold and the upper mold It protrudes into the other region located on the de body surface, and cover the pads exposed surface, in the seat pad, wherein the leading end portion of the tongue piece is engaged with the pad body portion of the other region.

  The vehicle seat pad and the manufacturing method thereof according to the present invention can take all possible measures to prevent abnormal noise due to rubbing against the seat frame and the like and to prevent the pad body from being broken, and improve workability and at low cost. Excellent effects such as being able to respond.

It is the perspective view which looked at the seat pad from the back side in one form of the seat pad of the present invention. It is the II-II arrow directional view of FIG. It is another aspect figure in the location of the tongue piece of FIG. It is explanatory sectional drawing which attaches the backing material with a tongue piece to an upper mold | type in a mold open state. (A) is a partial perspective view of a backing material with a tongue piece, (b) is another view of the backing material with a tongue piece instead of (a). 5A is an enlarged view around the protrusion of FIG. 4, and FIG. 5B is an enlarged view in which a backing material with a tongue piece is attached and set to the upper mold surface from FIG. It is explanatory drawing sectional drawing of the foaming type | mold which has inject | poured the foaming raw material in the mold open state. FIG. 8 is an explanatory sectional view of the foaming mold after FIG. It is the perspective view which looked at the seat pad of the prior art from the back side. FIG. 10A is a cross-sectional view around the exposed pad portion of FIG. 9, and FIG. 10B is an explanatory diagram of a problem when the seat frame is displaced to the exposed pad portion.

  Hereinafter, the seat pad and the manufacturing method thereof according to the present invention will be described in detail. 1 to 8 show one embodiment of a seat pad and a method for manufacturing the same according to the present invention. FIG. 1 is a perspective view of the seat pad as viewed from the back side, FIG. 2 is a view taken along the line II-II in FIG. Fig. 4 is another embodiment of the tongue piece in Fig. 2, Fig. 4 is an explanatory sectional view of attaching the backing material with the tongue piece to the upper die in the mold open state, and Fig. 5 is a partial perspective view of the backing material with the tongue piece. Figure, (b) is another embodiment of a backing material with a tongue piece instead of (a), FIG. 6 is an enlarged view around the protrusion of FIG. 4, (b) is a backing material with a tongue piece from (a) FIG. 7 is an explanatory cross-sectional view of a foaming mold in which a foaming raw material is injected in the mold open state, FIG. 8 is a view of FIG. It is explanatory sectional drawing of a type | mold. In order to make the drawings easy to understand, the thickness of the backing material and the tongue piece is illustrated as appropriate, and the foaming molds of FIGS.

(1) Seat pad The seat pad 1 is a back pad for a backrest or a cushion pad for receiving and supporting the lower body of a seated occupant. This embodiment is applied to a cushion pad as shown in FIGS. 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 1 includes a pad main body 2 made of a foam, a backing material 3 and a tongue piece 4.

The pad main body 2 is a foam molded product formed into a seat portion shape of a seat portion side cushion pad using a foamed resin raw material such as a polyurethane material (FIG. 1). In order to easily understand the periphery of the tongue piece 4 which is a characteristic part of the present invention, the seat pad 1 and the pad main body 2 of FIGS.
As shown in FIG. 2, the pad main body 2 includes a main portion 21 that supports an occupant's buttocks and thighs, and a side portion 22 that protrudes on both sides of the main portion 21 and supports the side portions of the buttocks and thighs. It is divided roughly into.

  The pad main body 2 is formed with a standing wall-like protruding portion 232 that protrudes toward the back surface side along the outer edge of the side portion 23 (FIG. 1). A standing wall-like overhanging portion 232 protrudes along the outer edge of the side portion of the pad body 2 toward the back surface. In addition, a central thickness portion 26 that maintains cushioning properties is provided in the central region of the pad main body back surface 2b, and the central thickness portion 26 and the overhang portion 232 form a recess u that runs in the vehicle front-rear direction. The seat frame F is disposed in the recess u, but the overhanging portion 232 is structurally lower as it approaches the back pad that is the rear of the vehicle (left side in FIG. 1). Accordingly, the seat frame F tends to be shifted laterally outward from the portion disposed at the rear of the vehicle. Reference numeral 24 denotes a portion corresponding to the overhang of the front portion, and the pad main body back surface 2b is surrounded in a U shape by the overhang portion 23 of the side portion 23. The symbol PL is a protruding parting line and is generated by the mating surfaces 69 and 79 of the lower die 6 and the upper die 7 (FIG. 8). Reference numeral 2A denotes one area of the pad body located on the pad body rear surface 2b side with respect to the partitioning line PL, and reference numeral 2B denotes another area of the pad body located on the pad body surface 2a side with respect to the partitioning line PL. Reference numeral 27 denotes a longitudinal groove.

The backing material 3 is a sheet-like body that is attached to and integrated with the back surface 2b of the pad body 2 (specifically, the region 2A side) by foam molding of the pad body 2. Here, a non-woven fabric is integrally formed on the back surface 2b of the pad body 2 by foam molding. Without weaving, the fabric is made into a sheet by fixing or intertwining the fibers mechanically, chemically, or thermally.
If the backing material 3 is provided cleanly all the way to the outer edge of the pad main body back surface 2b, it requires precision to set the mold 5 when manufacturing the seat pad and greatly increases the work time. Is slightly smaller than the outer peripheral edge of the back surface of the pad body 2. As shown in FIG. 1, the peripheral edge 31 of the backing material 3 set normally is located closer to the center of the pad body 2 than the outer edge of the back surface of the pad body 2, and the peripheral edge 31 of the backing material 3 and the back surface of the pad body 2. A margin for facilitating mold setting is provided between the outer edge (FIGS. 1 and 2). Due to the reduced backing material 3, a pad exposed surface 29 is formed between the backing material outer peripheral edge 31 and the back outer peripheral edge (pad side wall surface 231) of the pad body. The symbol ε indicates the width of the pad exposed surface 29 that appears due to the margin. Even if the backing material 3 is not integrally set with the pad main body 2 and set on the mold surface for forming the back surface 2b of the pad main body with high accuracy, the backing material 3 is not sandwiched between the foaming mold 5 by closing the mold. This has led to improved sex. In addition, while improving workability, the seat frame F hits the pad exposed surface 29 of the pad main body 2 in the margin with the seat pad rear surface 1b on the vehicle rear side as shown in FIG. Invite a bug.
When the frame is shifted to the pad exposed surface 29 side, problems such as the peeling surface 28 and the crack CK occur as described above, and the tongue piece 4 solves this problem.

  The tongue piece 4 is a protruding piece formed outwardly projecting on a part of the peripheral edge 31 of the backing material 3. As shown in FIGS. 1, 2, and 5 (B), a part of the sheet-like backing material 3 may be projected and extended outward as a tongue piece 4, but as shown in FIGS. 3 and 5 (A). It is more preferable that a part of the peripheral edge 31 of the backing material 3 and the separate sheet-like tongue piece 4 are stitched and extended outward. This is because it is possible to select tongue pieces such as weight and material that are effective in preventing abnormal noise. Although not shown, the tongue piece 4 and the backing material 3 in which a part of the backing material 3 is extended as shown in FIGS. 1, 2, and 5 (B) without the tongue piece 4 being separated. It is also preferable to add a stitched portion S to be a fold K at the boundary portion between the two. This is because the bulge at the bent portion K can be corrected with the stitching portion S to be small.

  This embodiment is the tongue piece 4 according to the backing material 3 with the tongue piece 4 in which a part of the backing material peripheral edge 31 is formed as a tongue piece 4 as shown in FIGS. Specifically, it is a backing material 3 with a tongue piece 4 as shown in FIG. Then, as shown in FIG. 1, the tongue piece 4 having the base 41 in one area 2A of the pad body protrudes into the other area 2B of the pad body beyond the parting line PL, and the tongue piece tip 45 is placed in the other area 2B. Lock to the pad body. The base 41 of the tongue piece 4 is a boundary portion with the backing material 3 and is integrally attached to the back surface 2b of the pad main body, but the main body portion 44 of the tongue piece 4 away from the base 41 is formed by foam molding of the seat pad 1. Prior to this, the base 41 shown by the chain line in FIG. At the time of foam molding, the folded main body 44 is hidden on the back side of the backing material 3. Therefore, the folded main body 44 is not coupled to the pad main body 2 or the backing material 3 even after foam molding. After demolding, the tongue piece 4 is raised and the tongue piece tip 45 is locked to the pad body portion of the other region 2B as shown in FIG. Here, one of the pair of hook-and-loop fasteners M1 is attached to the tip 45 of the tongue piece 4 as shown in FIG. 2, and the hook-and-loop fastener M is attached to the bad main body portion of the other region 2B where the tip 45 is locked. Attach the other M2 to ensure locking. One of the surface fasteners M1 stitched to the tongue piece 4 is set on the upper die 7, the other surface fastener M2 is set on the lower die 6, and both surface fasteners M1 and M2 are formed by foam molding of the pad body 2. It is integrated with the seat pad 1.

In another embodiment, the tongue piece 4 shown in FIG. 3 is obtained by combining the peripheral edge 31 of the backing material 3 and the base 41 of the separate tongue piece 4, and then along the backing material peripheral edge 31 together with the tongue piece 4. As shown in FIG. 5 (a), a stitched portion S that becomes a folded portion K is formed by the sewing thread ST, and the backing material 3 with the tongue piece 4 is integrated. Further, a recess 25 having a curved wall 252 that contacts the backing material 3 around the stitched portion S is provided in accordance with at least the width of the tongue piece 4 in the direction perpendicular to the plane of FIG. As will be described in the following manufacturing method, by providing a recess 25 by a protrusion 75 to be described in detail later, a foaming raw material to the tongue piece main body 44 folded on the back surface of the backing material 3 at the time of foam molding of the pad main body 2 g is difficult to enter. A similar recess 25 is provided in the pad main body 2 of FIGS.
In this way, the tongue piece 4 having the root 41 in one area 2A of the pad main body is engaged with the other area 2B of the pad main body beyond the parting line PL, and the pad exposure in the trouble occurrence area that generates abnormal noise and crack CK is generated. The desired seat pad 1 that covers the surface 29 and further has no foamed and hardened portion on the tongue piece 4 that covers the pad exposed surface 29 is obtained.

(2) Manufacturing method of seat pad The manufacturing method of the seat pad uses the backing material 3, the tongue piece 4, and the foaming mold 5, for example, the foaming mold 5 of FIGS. After the material 3 is set, the sheet pad 1 as shown in FIGS. 1 to 3 is formed through injection of the foaming raw material g and mold closing. 1, one tongue piece 4 may be provided, but in FIGS. 4 to 8, the foam pad 5 for the seat pad 1 is provided with two tongue pieces 4.
The backing material 3 and the tongue piece 4 are the same as those described in the seat pad 1 of (1), and detailed description thereof is omitted.

The foaming mold 5 used in the manufacturing method of the seat pad is a split mold as shown in FIGS. 4 to 8 and includes an upper mold 7 (one split mold) and a lower mold 6 (other split mold). When the mold is closed as shown in FIGS. 7 to 8 with a hinge (not shown) as a fulcrum, the mold surface 61 of the lower mold 6 having a large degree of dent and a mold surface 71 of the substantially flat upper mold 7 having a recess in part. Thus, the cavity C of the seat pad 1 in which the backing material 3 and the tongue piece 4 are integrated with the pad body 2 is formed. Reference numeral 61a denotes a main part forming part, reference numeral 61b denotes a side part forming part, and reference numeral 61c denotes a longitudinal groove convex part.
4 to 8, the front surface 1 a side of the seat pad is formed by the mold surface 61 of the lower mold 6, and the back surface 1 b side of the seat pad 1 is formed by the mold surface 71 of the upper mold 7. The tongue piece 4 of the backing material 3 with the tongue piece 4 is folded on the backing material 3 with the base 41 as a fold K, and set on the upper die 7. Therefore, the upper mold 7 is provided with a tongue piece setting step 711 as shown in FIG. Furthermore, the protrusion 75 is provided in the site | part of the upper mold | type 7 where the folding part K is distribute | arranged. A set of the backing material 3 with the tongue piece 4 on the upper mold 7 is provided with a projection 75 to be applied along the fold line K1 of the fold portion K, and a wall surface 752 of the projection 75 on the side facing the fold portion K. From the projecting upper end 751, the tongue piece 4 mounted and set on the upper mold 7 is formed into a curved surface that slopes downward toward the folding main body 44. The projection 75 forms an end surface at the projecting upper end 751, and a wall 753 opposite to the wall surface 752 facing the fold K is a substantially vertical surface. The protrusion 75 is formed in the shape of a bank in the direction perpendicular to the paper surface of FIG.

Here, the seat pad 1 shown in FIG. 3 is manufactured using the foaming mold 5, the backing material 3, and the tongue piece 4 as follows.
First, prior to foam molding, a separate tongue piece 4 is stitched to a part of the peripheral edge 31 of the backing material 3 to produce the backing material 3 with the tongue piece 4 (A in FIG. 5). The tongue piece 4 is sized so as to reach the other region 2B of the pad main body over the parting line PL as shown in FIG. Specifically, the sheet frame F has a rectangular size that can be prevented by covering the defective area such as the peeling surface 28 and the crack CK generated on the pad exposed surface 29 by being displaced by the tongue piece 4. The rectangular tongue 4 is connected to the backing material 3 by forming a stitched portion S with the backing material 3 at the base portion as shown in FIG. The stitched portion S becomes a bent portion K of the tongue piece 4 and the backing material 3.

Then, the backing material 3 with the tongue piece 4 is set on the upper mold 7 with the foaming mold 5 in the mold open state. The tongue piece 4 is folded on the backing material 3 with the base 41 as a fold K and hidden behind the backing material 3, and the backing material 3 with the tongue piece 4 is set on the upper mold surface 71. (FIG. 4).
Specifically, it is mounted and set as shown in FIG. As shown in FIG. 6 (a), the base 41 of the tongue piece 4 and the portion of the backing material peripheral edge 31 sewn to the tongue piece 4 are aligned with the edge where the protruding upper end 751 of the protrusion 75 contacts the curved wall surface 752. Subsequently, the base 41 of the tongue piece 4 and the portion of the backing material peripheral edge 31 sewn to the tongue piece 4 are pressed against the upper mold surface 71 together with the other backing material 3 with the tongue piece 4, and the upper mold 7. Install and set to. The tongue piece 4 is attached to and set on the upper die 7 so that the base 41 is folded over the backing material 3 with the base 41 being a fold K and hidden behind the backing material 3 (b in FIG. 6). Here, the wall surface 752 of the projection 75 on the side facing the folding portion K is formed on a curved surface that is inclined downward from the projecting upper end 751 toward the folding body portion 44 of the tongue piece 4 attached and set to the upper mold 7. Therefore, the bent portion K is set so as to be applied to the curved surface. The base 41 of the tongue piece 4 and the portion of the backing material peripheral edge 31 are set on the upper mold surface 71 while rubbing the curved surface from FIG. 6 (a) to FIG. 6 (b). The base 41 of the tongue piece 4 and the backing material peripheral edge 31 are in contact with the protrusions 75, and are in close contact with the protrusions 75. In FIG. 6B, a gap is provided between the folded main body 44 and the curved wall surface 752 for easy understanding of the drawing.

On the backing material 3, rectangular ferrite sheet pieces T are bonded and integrated at appropriate intervals along the outer peripheral edge thereof. Ferrite sheet pieces T are arranged on portions of the backing material 3 on both sides of the tongue piece 4 (FIG. 5). On the other hand, a magnet (not shown) is embedded in a portion corresponding to each ferrite sheet piece T of the upper mold surface 71.
Thus, the periphery of the tongue piece 4 is slightly pressed toward the upper mold surface 71, and the folding portion K, particularly the portion of the backing material peripheral edge 31 where the base 41 of the tongue piece 4 and the tongue piece 4 are located on the protrusion 75, is formed on the protrusion 75. 6 is abutted and brought into close contact with the curved wall surface 752 by rubbing from (a) to (b) in FIG. And the ferrite sheet piece T is made to adsorb | suck to a magnet, and the setting of the backing material 3 with the tongue piece 4 to the upper type | mold surface 71 is completed.

Thereafter, after the foaming raw material g is injected and the mold is closed, the pad main body 2 made of the foam is integrally foam-molded with the backing material 3 with the tongue piece 4 disposed on the back surface 2b.
In this embodiment, after the backing material 3 with the tongue piece 4 is set on the foaming mold 5, the pad surface is formed using the injection hose NL or the like on the mold surface 61 that forms the cavity C of the lower mold 6 while the mold is open. A predetermined amount of a foaming raw material g such as a main body molding urethane foam stock solution is injected (FIG. 7). Subsequently, the upper die 7 is operated to close the die (FIG. 8). By closing the upper die 7 and the lower die 6, the cavity C for the seat pad 1 into which the backing material 3 with the tongue piece 4 is inserted is formed. In addition, after setting the backing material 3 with the tongue piece 4 to the foaming mold 5, the foaming raw material g was injected and then the mold was closed, but after setting the backing material 3 and the tongue piece 4 to the foaming mold 5, It is also possible to close the mold and then inject the foaming raw material g.

  After closing the mold, the process proceeds to foam molding of the pad body 2. The pad main body 2 is integrally foam-molded with the backing material 3 with the tongue piece 4. 8 is maintained for a predetermined time, the backing material 3 is integrally attached to the back surface 2b side of the pad main body 2, and the tongue piece 4 is not impregnated with the foaming raw material g except at least at the base 41 region. Every three seat pads 1 are made.

  In the foam molding process, the foaming raw material g approaches the upper mold surface 71 and reaches the backing material 3, and further, at the bent portion K, specifically, at the base 41 of the tongue piece 4 and the backing material peripheral edge 31. An attempt is made to enter the folded main body 44 of the tongue piece 4 through the gap between the portion and the upper mold surface 71. However, the folded portion K does not bulge due to the formation of the stitched portion S so that it can be folded back when it is simply folded as shown in FIG. The portion of the tongue piece 4 that is folded back is in contact with and closely adhered to the backing material 3, and the tongue piece 4 is hidden by the backing material 3. Prevent entry of raw material g. Further, the base 41 of the tongue piece 4 related to the bent portion K and the portion of the backing material peripheral edge 31 that overlaps the tongue piece 4 abut on the curved wall surface 752 of the protrusion 75 provided on the upper mold 7, and the backing material 3. The foaming raw material g is prevented from wrapping around the folded main body 44 of the tongue piece 4 disposed on the back surface. A fold K including the base 41 of the tongue piece 4 and the backing material peripheral edge 31 where the tongue piece 4 folds abuts and comes into close contact with the curved wall surface 752 of the protrusion 75, and moves toward the folded main body 44 of the tongue piece 4. The inlet for the foaming raw material g is closed. The foaming raw material g which is going to enter the folded main body 44 of the tongue piece 4 from the base 41 of the tongue piece 4 or the peripheral edge 31 side of the backing material 3 overlapping with the tongue piece is stopped by the protrusion 75.

  When the foam molding of the pad main body 2 is finished and removed, the backing material 3 made of nonwoven fabric is adhered and integrated on the back surfaces of the main portion 21 and the side portion 22, and the base 41 of the tongue piece 4 is integrated with the pad main body 2. The obtained seat pad 1 is obtained. A recess 25 is formed in the pad main body 2 by the protrusion 75. The projecting upper end 751, the opposing wall surface 752, and the rear side wall surface 753 of the projection 75 serve as a recess bottom 251, a curved wall 252, and a standing wall 253, respectively. The seat pad 1 is in contact with the backing material 3 and the folded main body 44 shown by a chain line in FIG. 3, but the foam raw material g is not impregnated into the back surface of the backing material 3 during foam molding. Since the foaming raw material g is prevented from moving from the folded portion K to the folded main body portion 44 by the protrusion 75, there is no connection between the backing material 3 and the folded main body portion 44 of the tongue piece 4.

  After demolding, the tongue piece 4 that has been folded up is raised, and it is tilted from one area 2A of the pad body in the fold K to the other area 2B side of the pad body beyond the parting line PL. The tip 45 of the piece 4 is locked to the pad body 2 in the other area 2B. Further, one side M1 of the hook-and-loop fastener M is provided on the tongue piece 4, and the other M2 is provided on a surface facing the tip portion 45 of the tongue piece that is tilted on the other region 2B side of the pad body 2, and the hook-and-loop fasteners M1 and M2 are provided. By joining and fixing, a desired seat pad 1 is produced in which the tongue piece 4 covers the pad exposed surface 29 which becomes a failure occurrence area and the locking is strengthened. When the seat pad 1 is covered with an unillustrated skin, it becomes a seat cushion for a seat of a vehicle seat.

(3) Effect According to the seat pad 1 configured as described above and the manufacturing method thereof, the other area 2B of the pad body where the tongue piece 4 exceeds the parting line PL from the one area 2A of the pad body at the base 41 thereof. Therefore, the pad exposed surface 29 that causes a problem can be easily covered. The seat frame F rubs against the pad exposed surface 29, which is difficult to deal with on the back surface 2b of the pad body, with the side wall surface 231 of the side portion 23, causing abnormal noise, peeling surface 28, and crack CK. To solve the problem.

Further, when the stitched portion S is formed in the folded portion K connected to the backing material 3 and the tongue piece 4, the bulge that can be formed in the folded portion when simply folded as shown in FIG. It is possible to prevent the foaming raw material g from entering from the bent portion K to the tongue piece main body portion 44. The foaming hardening part of the foaming raw material g does not appear in the folded body part 44 of the tongue piece 4 after the foam molding. It is possible to prevent noise generation due to rubbing with the seat frame F or the like.
Further, when the stitched portion S is formed, a separate tongue piece 4 can be connected to the backing material 3. Since the tongue piece 4 separate from the backing material 3 can be used, the tongue piece 4 made of material or material that can effectively and effectively eliminate the peeling surface 28 and the crack CK on the pad exposed surface 29 is supported. It can be selected independently without being restricted by the material 3. For a long period of time, it is possible to manufacture a seat pad 1 that is superior in preventing the generation of abnormal noise due to rubbing with the seat frame F and the like and preventing the pad body 2 from being torn.

In addition, if the wall surface 752 of the protrusion 75 is formed on a curved surface that is inclined downward from the upper end 751 of the protrusion 75 toward the folded main body 44 of the tongue piece 4, the backing material with the tongue piece 4 is provided. When setting 3 to the upper mold 7, the bent portion K of the backing material 3 with the tongue piece 4 can be in close contact with the projection 75 so that the bent portion K is applied to the curved surface as shown in FIG. 6. Unlike patent document 1 in which the foaming raw material g is easy to enter, the curved wall surface 752 of the protrusion 75 is present, so that the foaming raw material g can be prevented from entering. Therefore, it is possible to prevent the foaming raw material g from entering the gap between the backing material 3 with the tongue piece 4 and the upper mold 7 from the bent portion K and entering the tongue piece main body 44 in the foam molding process. Since the foaming raw material g enters the portion corresponding to the seat pad back surface 1b side of the tongue piece 4 and does not foam and cure, no abnormal noise occurs. Moreover, it is very easy to set the backing material 3 with the tongue piece 4 on the upper mold 7 from (a) to (b) in FIG. 6, unlike the invention of Patent Document 2, as shown in FIGS. Thus, the setting operation to the foaming mold 5 can be smoothly advanced. The work in foam molding does not require high accuracy and the work load is small. Workability can be improved and low cost can be dealt with.
Thus, this seat pad 1 and its manufacturing method exhibit the various outstanding effects mentioned above, and are very useful.

  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 seat pad 1, the pad body 2, the backing material 3, the tongue piece 4, the foaming mold 5 and the like 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.

1 Seat pad 2 Pad body 2A One area of the pad body 2B Other area of the pad body
2a Pad body surface
2b Back side of pad body
29 Pad Exposed Surface 3 Backing Material
31 Periphery of backing material 4 Tongue piece 41 Base 45 Tip
6 Lower mold
69 Mating surface 7 Upper mold 79 Mating surface 75 Projection (bank-like projection)
752 Curved wall (opposite wall)
g Foaming raw material K Folding part M Surface fastener PL Parting line S Stitching part

Claims (4)

In a method for manufacturing a seat pad for a vehicle seat,
A backing material with a tongue piece in which a tongue piece extends outward is formed on a part of the peripheral edge of a sheet-like backing material that is integrally adhered to the back surface of the pad body by foam molding, After the tongue piece is folded at the base of the fold and hidden in the backing material and set in one split mold, the pad body is integrally foamed with the backing material with the tongue piece, and then removed. Then, the tongue piece that has been folded is raised, and the tongue piece is brought down from one area of the pad body at the folding portion to the other area side of the pad body beyond the parting line, A seat pad manufacturing method, wherein the front end of the seat pad is locked to the pad body in the other region. The tongue in which the one split mold is provided with a protrusion to which the bent portion of the tongue piece is applied, and the wall surface of the protrusion on the side facing the bent section is set to the one split mold from the upper end of the protrusion 2. The backing material with a tongue piece is set in one split mold so as to be formed on a curved surface that is inclined downward toward the folded body portion of the piece, and the folded portion is applied to the curved surface. The manufacturing method of the seat pad of description. The manufacturing method of the seat pad of Claim 1 or 2 which formed the stitching | suture part in the said bending part with which the said backing material and the said tongue piece connect. In a seat pad for a vehicle seat comprising: a pad body made of foam; and a sheet-like backing material that is integrally attached to the back surface by foam molding of the pad body.
The periphery of the backing material is located closer to the center of the back surface of the pad body than the outer edge of the back surface of the pad body, and a margin is provided between the periphery of the backing material and the outer edge of the back surface of the pad body, A pad exposed surface is formed between the outer periphery of the backing material and the outer periphery of the back surface of the pad body,
Further, a backing material with a tongue piece formed by extending a sheet-like tongue piece outwardly to a part of the peripheral edge of the backing material or by stitching a separate tongue piece and extending outward. is formed, standing tongue piece, from one region of the pad body located in the pad body rear surface side of the base, the pad body surface beyond the party Grinding caused by mold face of the lower mold and the upper mold The seat pad is characterized in that it protrudes to the other region, covers the pad exposed surface, and the tip of the tongue piece is locked to the pad main body portion of the other region.

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