JP6643947B2 - Vehicle cushion pad and manufacturing method thereof - Google Patents

Description

  The present invention relates to a vehicle cushion pad that constitutes a seat portion of a vehicle seat, and a method of manufacturing the same.

The seat cushion, which constitutes the seat of a seat mounted on a vehicle such as an automobile, is a portion where an occupant sits down and comes into direct contact with the occupant. I may feel it. In view of the above, the present applicant has proposed a ducted seat cushion in which a duct for air distribution through which temperature-regulated air can be sent is inserted, and at least a seat surface to which an occupant abuts is integrally formed of a flexible polyurethane foam. (Japanese Patent Application Laid-Open No. 2011-110366).
On the other hand, in recent years, there has been a movement to promote weight reduction and to reduce the amount of high-cost urethane used in vehicle cushion pads for popular vehicles, and inventions responding to this have been proposed (for example, Patent Document 1).

JP-A-9-70330

  However, claim 1 of Patent Literature 1 claims “a layered different hardness pad for a vehicle seat comprising two upper and lower foam layers, wherein the upper layer is formed of polyurethane foam and the lower layer is formed of polystyrene foam. And the upper and lower layers are integrally joined. A layered different hardness pad for a vehicle seat. ", And it was difficult to embed and integrate the air distribution duct. A layered pad of different hardness ("cushion pad" in the present invention) may be required to provide air distribution passages to blow air whose temperature has been adjusted, and in such a case, there is a problem that it is difficult to cope with the case.

  The present invention solves the above-mentioned problem, and provides an air distribution channel inside the pad to enable air to be blown at a controlled temperature, and realizes a lightweight cushion and a reduced amount of urethane used, and a cushion pad for a vehicle. It is intended to provide a manufacturing method.

In order to achieve the above object, the gist of the present invention according to claim 1 is a vehicle cushion pad having at least a seat surface to which an occupant abuts is made of a soft polyurethane foam and provided with an air distribution channel, A core pad made of a non-breathable foam, provided with an air distribution channel recess on the back side, and provided with a plurality of through-holes penetrating from the concave bottom of the recess to the front side, and a soft polyurethane foam The seat surface portion is provided on the design surface side, an inner surface side opposite to the design surface side is bonded to the surface of the core pad, and a plurality of air blowing holes penetrating from the inner surface side to the design surface side are provided. An upper layer pad provided and arranged so that the air blowout holes are respectively connected to the through holes, and a non-breathable foam, and the upper surface side is formed with the opening of the recess so as to form an air distribution channel. Cover, bonded to the back of the core pad, A lower layer pad provided with an air introduction hole penetrating from the lower surface side into the air distribution channel, and the apparent density of the non-breathable foam is smaller than the apparent density of the flexible polyurethane foam. A cushion pad for a vehicle, characterized in that: According to a second aspect of the present invention, in the vehicle cushion pad according to the first aspect, the air-impermeable foam of the core pad and the lower layer pad is a molded article of expanded polypropylene or expanded polystyrene. The vehicle cushion pad according to the third aspect of the present invention is the vehicle cushion pad according to the first or second aspect, in which the back surface side of the core pad carries the side wall of the dent and protrudes from the bottom surface to the back surface side to partition the dent. The present portion is formed to extend in a peninsula shape, and the back surface of the extending portion is formed to be a flat surface. According to a fourth aspect of the present invention, in the vehicle cushion pad according to the third aspect, the back surface of the peripheral portion surrounding the recess is formed as a step surface recessed in a step shape from the back surface of the core pad. The back surface of the extending portion is formed as a uniform flat surface.
The gist of the invention according to claim 5 is a method for manufacturing a cushion pad for a vehicle having a ventilation channel, wherein at least a seat surface portion to which an occupant abuts is made of a flexible polyurethane foam, A core pad formed of a non-breathable foam smaller than a flexible polyurethane foam, provided with a ventilation passage recess on the back surface, and provided with a plurality of through holes penetrating from the recess bottom to the front surface side of the recess. A plurality of pins protruding from the upper mold surface of the foaming mold are respectively inserted into the through holes according to (1) and the back side of the core pad is brought into contact with the upper mold surface, and the core pad is brought into contact with the upper mold surface. Then, the raw material for the flexible polyurethane foam is poured onto the lower mold surface, and then the tip of the pin is brought into contact with the lower mold surface forming the seat surface portion to close the mold. Then, a seat surface portion is provided on the design surface side, and the inner surface side of the core pad is The upper layer pad of the flexible polyurethane foam bonded to the surface is foam-molded, and then the mold is released. Covering the opening of the dent so as to form an air distribution passage on the upper surface side of the lower layer pad having the air introduction hole penetrated to the upper surface side, and conducting the air introduction hole into the air distribution passage, thereby forming the core pad A method of manufacturing a cushion pad for a vehicle, wherein the lower layer pad is bonded to a back surface of the vehicle. According to a sixth aspect of the present invention, in the method for manufacturing a cushion pad for a vehicle according to the fifth aspect, the air-impermeable foam of the core pad and the lower layer pad is a molded article of expanded polypropylene or expanded polystyrene. The manufacturing method of the cushion pad for a vehicle according to the invention of claim 7 is the method according to claim 5 or 6, wherein the back surface of the core pad carries the side wall of the recess and is raised to the back surface side from the bottom surface of the recess. Is formed to extend in the shape of a peninsula, and the back surface of the extending portion is formed as a flat surface, and the back surface of the peripheral portion surrounding the recess is recessed stepwise from the back surface of the core pad. And the stepped surface and the back surface of the extending portion are formed as a uniform flat surface.

  The vehicle cushion pad and the method of manufacturing the same according to the present invention are characterized in that the seat portion is formed of an upper layer pad of a flexible polyurethane foam, while the apparent density is smaller than the apparent density of the flexible polyurethane foam. The lower layer pad and the core pad constitute a low-cost air distribution channel, air introduction hole, and through hole, and the upper layer pad has an air outlet hole that communicates with the through hole. While maintaining the air conditioner, it is possible to reduce the weight and to exert an excellent effect such that the air whose temperature is adjusted can be sent to the seated occupant.

BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory sectional drawing which sets a core pad to the foaming mold in a mold open state, and injects foaming raw material in one form of the cushion pad of this invention, and its manufacturing method. FIG. 2 is an explanatory cross-sectional view showing a state in which the mold is closed after the injection of the foaming raw material in FIG. 1. It is explanatory sectional drawing which carried out foam molding of the upper layer pad with a core pad. FIG. 6 is an explanatory sectional view of a cushion pad formed by joining a lower pad to the upper pad with a core pad of FIG. FIG. 4 is a perspective view of an upper layer pad with a core pad and a lower layer pad of FIG. 3 from which the mold is removed. FIG. 5 is a corresponding perspective view of the cushion pad shown in FIG. It is the perspective view which looked at the cushion pad of FIG. 6 from the design surface side. FIG. 6 is a perspective view of a core pad and a lower layer pad of another embodiment instead of FIG. 5. FIG. 2 is an explanatory cross-sectional view illustrating an open state of a mold for forming an upper layer pad and corresponding to FIG. 1. FIG. 4 is an explanatory sectional view corresponding to FIG. 3. It is explanatory sectional drawing of the upper layer pad with a core pad of another mode, and a lower layer pad. It is explanatory sectional drawing which joined the lower layer pad to the core pad of FIG. 11, and was set as the cushion pad.

Hereinafter, a vehicle cushion pad according to the present invention (hereinafter, also simply referred to as a “cushion pad”) and a method of manufacturing the same will be described in detail. 1 to 12 show an embodiment of a cushion pad and a method of manufacturing the cushion pad according to the present invention. FIG. 1 is an explanatory cross-sectional view in which a core pad is set in a foaming mold in an open state used for the method and a foaming material is injected. FIG. 2 is an explanatory sectional view in which the mold is closed after the injection of the foaming raw material in FIG. 1, FIG. 3 is an explanatory sectional view in which the upper pad with a core pad is foamed, and FIG. FIG. 5 is an explanatory sectional view showing a cushion pad formed by joining lower pads, FIG. 5 is a perspective view of an upper pad with a core pad and a lower pad shown in FIG. 3, and FIG. 6 is a corresponding perspective view of the cushion pad shown in FIG. 7 is a perspective view of the cushion pad of FIG. 6 as viewed from the design surface side, FIG. 8 is a perspective view of a core pad and a lower layer pad of another embodiment instead of FIG. 5, and FIG. 9 is an explanation of a mold open state corresponding to FIG. FIG. 10 is an explanatory sectional view corresponding to FIG. 1 is an explanatory cross-sectional view of the upper pad and the lower padded core pads 10, FIG. 12 is an explanatory sectional view of a cushion pad bonded to the lower pad core pad of Figure 11. The core pad shown in FIG. 9 corresponds to the view taken along line IX-IX in FIG.
Each drawing shows a simplified diagram for easy understanding of the drawings, and portions not directly related to the present invention are omitted. The core pad 2 and the lower layer pad 6 omit the hatching of the sectional display.

(1) Manufacturing Method of Cushion Pad for Vehicle The manufacturing method of the cushion pad for a vehicle is such that at least the seat surface portion 41 with which the occupant abuts is made of a flexible polyurethane foam, and the cushion pad for a vehicle provided with the air distribution channel u. It is a manufacturing method. Using the foaming die 7, the core pad 2 is inserted, and the upper pad 4 of the soft polyurethane foam is foamed to form the upper pad 4 with the core pad 2. After removal from the mold, the lower pad 6 is joined to the back surface 2b of the core pad to produce the cushion pad P. The cushion pad P is used for a seat portion of a seat such as a rear seat for a vehicle, a driver's seat, a passenger seat, and the like. Here, the present invention is applied to a cushion pad P of a driver seat as shown in FIG. Prior to the foam molding of the upper layer pad 4, the core pad 2, the lower layer pad 6, and the foam mold 7 are prepared.

The core pad 2 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 a core member disposed on the back side of the cushion pad P as shown in FIG. It is. The density comparison between the core pad 2 and the upper layer pad 4 is not based on the density of the material before foaming but on the apparent density after foaming.
Prior to the foam molding of the upper layer pad 4, the core pad 2 and the lower layer pad 6 which have been foam molded in advance are prepared. The core pad 2 is provided with a recess 21 for the air distribution channel u having the size of the rear half on the back surface 2b side, and a plurality of through holes 23 penetrating from the concave bottom 211 of the recess 21 to the front surface 2a side. (FIGS. 2 and 5). In this embodiment, the air flow distribution channel recess 21 has a dish-like shape and is substantially squarely recessed as shown in FIG. The number of the through holes 23 is four. Here, the “front side” and “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 surface side” and “inside surface” of the upper layer pad 4 and the “upper surface side” and “lower surface side” of the lower layer pad 6 are also similar to the cushion pad P in FIG. The front side "and the" back side "of the paper surface have the same meaning. Words are used properly to make it easier to identify the part.
The back surface along the peripheral portion surrounding the recess 21 is formed as a step 26 having a step surface 261 recessed in a step-like manner from the back surface 2b of the core pad 2 via a drop wall 262 (FIG. 1), and has a substantially constant width. The surface 261 is formed as a uniform flat surface. Reference numeral 28 denotes an upper end surface of a protruding portion that protrudes outward from the core pad 2 when the core pad 2 is set in the foam mold 7. Reference numeral 29 denotes an opening provided in the core pad 2, 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 2 is set on the upper die 9 as shown in FIG. 2, a space is secured between the receiving surface 293 and the upper die surface 91.

4 and 5, the lower pad 6 is made of a non-breathable foam, and the upper surface 6a covers the opening 210 of the recess 21 so as to form an air distribution channel u. It is bonded to the back surface 2b of the pad 2. The lower surface 6b of the lower layer pad 6 joined to the core pad back surface 2b has a shape conforming to the back surface of the cushion pad P. An air introduction hole 61 penetrating from the lower surface 6b side of the lower layer pad 6 into the air distribution channel u is provided.
The apparent density of the impermeable foam constituting the lower pad 6 is smaller than the apparent density of the flexible polyurethane foam. The non-breathable foam constituting the lower pad 6 (and the core pad 2) satisfies if the apparent density is smaller than the apparent density of the soft polyurethane foam forming the upper pad 4; Alternatively, a molded article of styrene foam is more preferable. For example, the styrofoam molded article of the bead method styrofoam is a non-breathable foam in which air bubbles are sealed inside, and the air distribution channel u in which the depression 21 of the core pad 2 and the depression 21 are covered by the lower layer pad 6. Does not leak air-conditioning air. In addition, most of the volume is made of gas and light, so that the apparent density can be made smaller than the apparent density of the flexible polyurethane foam. The foamed polypropylene of the bead method foamed polypropylene is also very similar to styrofoam, and is made of a non-breathable foam in which air bubbles are sealed. And the apparent density can be reduced. The non-breathable foam of the lower pad 6 may be different from the non-breathable foam of the core pad 2, but using the same material facilitates the manufacture of the cushion pad P. The same material of expanded polypropylene is used for the core pad 2 and the lower layer pad 6 of the present embodiment. Expanded polypropylene is more elastic than expanded polystyrene (styrene foam), and is more preferable as a constituent material of the cushion pad core pad 2 and the lower layer pad 6.
Reference numeral 63 denotes a recess in which the portion of the lower pad upper surface 6a that covers the opening 210 of the recess 21 is dented so that the cross-sectional area of the air distribution channel u increases.

  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 openable and closable. When the mold is closed as shown in FIG. 2 with the hinge 71 as a fulcrum, the whole is concavely shaped like a bowl and the lower mold surface 81 forming the design surface 4a of the seat surface portion 41, and the whole having a dent at the center is slightly convex. The cavity C of the upper layer pad 4 with the core pad 2 is formed with the upper die surface 91 that matches the back surface 2b of the core pad 2. A plurality of pins 92 stand on the upper die surface 91. Each pin 92 has a pin diameter substantially equal to the hole diameter of the through hole 23 and a long pin length, and is set on the upper die surface 91 of the core pad 2, and is inserted through each through hole 23 and protrudes from the core pad 2. In the present embodiment, four pins 92 are formed so as to protrude from the upper die surface 91 corresponding to the four through holes 23. When the mold is closed, the tip of each pin 92 abuts on the lower mold surface 81 as shown in FIG. The foaming mold 7 shown in FIGS. 1 to 3 is a mold structure for forming the upper pad 4 with the core pad 2 according to the cushion pad P in an upside-down state with respect to the cushion pad P shown in FIG. It has become.

Using the foam mold 7, the core pad 2, and the lower layer pad 6, the cushion pad P is manufactured as follows, for example.
First, the foam mold 7 is set to the mold open state in FIG. The core pad 2 is set on the upper mold 9 in this mold open state. A plurality of pins 92 are inserted into the respective through holes 23 provided in the core pad 2, and the core pad back surface 2 b having the recess 21 in the upper die surface 91 is brought into contact with the upper die surface 91, so that the core pad 2 is It is set on the mold surface 91. The upper mold surface 91 also contacts the concave bottom 211 of the concave 21.
After the core pad 2 is set on the upper die surface 91, a foaming raw material g for forming the upper pad 4 using the injection nozzle NL or the like (a raw material for a flexible polyurethane foam) is formed on the lower die surface 81 which is recessed in a bowl shape using an injection nozzle NL or the like. Is injected in a predetermined amount.

  Next, the tip of the pin 92 is brought into contact with the lower mold surface 81 forming the seat surface portion 41 of the cushion pad P to close the mold. In addition, the pin contact portion 83 of the lower mold surface 81 with which the pin 92 contacts when the mold is closed is slightly raised in a curved surface shape as shown in FIG. 2, and the pin 92 surrounds the outlet of the air blowing hole 45 formed in the upper layer pad 4. Has a clean design surface 4a.

After the mold is closed, the upper layer pad 4 made of a flexible polyurethane foam and having the seat surface portion 41 on the design surface 4a side is foam-formed. The inner surface 4b opposite to the design surface 4a of the upper pad 4 is joined to the surface 2a of the core pad 2 to form the upper pad 4 with the core pad 2. In the foam molding process, the foaming raw material g injected into the cavity C around the pin 92 protruding from the core pad 2 is foamed and formed as the upper layer pad 4, and the pin 92 protruding from the core pad 2 forms the air blowing hole 45. I do. Since each pin 92 forming the air outlet 45 is inserted into the through hole 23, each air outlet 45 is electrically connected to each through hole 23.
By the way, even if the upper layer pad 4 of the flexible polyurethane foam is foamed, it has poor adhesion to the non-breathable foam such as foamed polypropylene and styrofoam which constitute the core pad 2, and it is not possible to integrate the two as it is. There is a possibility that it will be sufficient. Although both sides may rely on a double-sided tape or an adhesive, in the present embodiment, as shown in FIG. 1, the core pad 2 is provided with an opening 29 having a receiving surface 293, and a protruding portion where the upper end surface 28 becomes substantially horizontal at the time of setting. It is formed so as to integrate the core pad 2 and the upper layer pad 4. At the time of foam molding of the upper layer pad 4, the foaming raw material g goes under the small diameter portion 292 of the opening 29, and the foaming raw material g infiltrates on 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, and the core pad 2 and the upper layer pad 4 are integrated (FIG. 3). Also, by foaming the upper layer pad 4, the upper layer pad 4 rides on the upper end surface 28 of the protruding portion of the core pad 2 as shown in FIG. ing.

When the foam molding of the upper pad 4 is completed and the mold is removed, the upper pad 4 with the core pad 2 is obtained. When the upper mold 9 is opened at the time of removing the mold, the upper pad 4 with the core pad 2 having been subjected to the foam molding appears on the upper mold 9 side while being held by the pins 92. The worker can detach the upper pad 4 with the core pad 2 from the pin 92 in a comfortable posture while standing.
Thereafter, the upper surface 6a of the lower layer pad 6 penetrating the air introduction hole 61 covers the opening 210 of the recess 21 so as to form the air distribution channel u, and connects the air introduction hole 61 with the air distribution channel u. The lower layer pad 6 is bonded to the back surface 2b of the core pad 2 (FIG. 4). Reference numeral 661 denotes a contact surface on the lower layer pad 6 side that is joined to the step surface 261 of the core pad back surface 2b. The lower layer pad 6 is bonded to the core pad back surface 2b by covering the opening 210 of the recess 21 so as to form the air distribution channel u on the lower layer pad upper surface 6a side, and a desired vehicle cushion pad as shown in FIGS. P. If a cover (not shown) is put on the cushion pad P, a seat cushion of the vehicle seat is completed.
The bonding between the lower layer pad 6 and the core pad 2 is performed by integral bonding with a double-sided tape interposed therebetween or adhesive bonding with an adhesive. In the drawing, reference numeral 84 denotes a lateral groove forming portion, reference numerals 89 and 99 denote a mating surface, reference numeral 4A denotes a main portion, reference numeral 4B denotes a side portion, reference numeral 4C denotes a joining portion with a backrest, and reference numeral 49 denotes a suspension groove. Reference numeral 491 denotes a vertical groove, and reference numeral 492 denotes a horizontal groove.

8 to 12 illustrate a method of manufacturing a cushion pad P according to another embodiment instead of FIGS. 1 to 7.
Here, a core pad 2 and a lower layer pad 6 as shown in FIG. 8 are prepared. The lower layer pad 6 is a disk-shaped body as shown. The core pad 2 is provided with an extended portion 25 that protrudes into the recess 21 on the back surface side while forming a recess 21 that is largely concave in a dish-like and substantially square shape as shown in FIGS. An extended portion 25 that bears the side wall 212 of the recess 21 and rises toward the back surface 2b from the bottom 211 of the recess 21 so as to divide the rectangular recess 21 into approximately two parts is formed to extend in a peninsula shape. You. The term “partitioning the dent 21” as used in the present invention means that the air-conditioning air flows inside the dent 21 by the extending portion 25 as shown in FIG. 8, and the dent 21 is not divided. The back surface 25b of the extension portion 25 is formed as a flat surface as shown. Further, a back surface 22b of the peripheral portion 22 surrounding the recess 21 is formed on a step surface 261 recessed in a step-like manner from the back surface 2b of the core pad 2, and the step surface 261 and the back surface 25b of the extending portion 25 are in one position. The core pad 2 is formed on such a flat surface. The portion of the lower layer pad 6 that is joined to the extending portion 25 and the step surface 261 face to face is also a uniform plane. When the lower layer pad 6 covers the opening 210 of the recess 21 to form the air distribution channel u, the lower layer pad 6 is tightly joined to the extending portion 25 and the step surface 261.
Although the number of air introduction holes 61 provided in the lower layer pad 6 in FIG. 8 is one as in FIGS. 1 to 7, the number of through holes 23 provided in the core pad 2 is six.
The foaming mold 7 having a cavity C corresponding to the core pad 2 and the upper layer pad 4 is prepared. Six pins 92 stand on the upper die surface 91 at positions corresponding to the six through holes 23 of the core pad 2.

A cushion pad P shown in FIG. 12 in another mode instead of FIG. 4 is manufactured as follows using the core pad 2, the lower layer pad 6, and the foam mold 7 of FIGS.
First, under the mold open state of FIG. 9, each pin 92 protruding from the upper mold surface 91 is inserted into each through hole 23 of the core pad 2 and the core pad back surface 2b side is brought into contact with the upper mold surface 91. Then, the core pad 2 is set. Here, when setting the core pad 2 in the foaming mold 7, the core pad back surface 2 b having the recess 21 on the upper mold surface 91 is brought into contact with the upper mold surface 91, but as shown in FIG. Does not abut. The corresponding portion of the upper mold surface 91 is in contact with the step surface 261 around the recess 21 so as to abut and seal, and the inside of the recess 21 is kept empty. The upper die 9 has a die surface 91 without a die surface portion projecting into the recess 21.

Next, the raw material g for the flexible polyurethane foam is poured onto the lower die surface 81, and the tip of the pin 92 is brought into contact with the lower die surface 81 forming the seat surface portion 41 to close the die. .
Subsequently, the upper pad 4 which is a soft polyurethane foam having the seat surface portion 41 on the design surface 4a side is foam-formed (FIG. 10) to obtain the upper pad 4 with the core pad 2. The inner surface 4 b side of the upper pad 4 is joined to the surface 2 a of the core pad 2. Here, the core pad 2 set on the upper mold 9 as shown in FIG. 10 is provided with a projecting portion 271 projecting horizontally outward on the side near the lower mold surface 81 in the cavity C, while On the side close to the mold surface 91, there is provided a retreating portion 272 which retracts inward horizontally. The upper layer pad 4 is foam-molded as the upper layer pad 4 with the core pad 2 in such a manner that the upper layer pad 4 covers the retreating portion 272 and enfolds the overhang portion 271 so that the two are integrated.

  Thereafter, the upper layer pad 4 with the core pad 2 is released. Thereafter, the upper layer pad 4 with the core pad 2 removed is covered with the opening 210 of the recess 21 so as to form the air distribution channel u on the upper surface side of the lower layer pad 6, and the air introduction hole 61 is provided with the air distribution channel u. The lower layer pad 6 is joined to the back surface 2b of the core pad so as to conduct into the inside, thereby forming a desired cushion pad P (FIGS. 11 and 12). Bonding between the core pad back surface 2b and the lower layer pad 6 is performed by adhesive bonding with an adhesive or the like interposed therebetween. The other configuration is the same as the description of the cushion pad P in FIGS. 1 to 7, and the description is omitted. 1 to 7 indicate the same or corresponding parts.

(2) Cushion pad The cushion pad P obtained by the above-described manufacturing method shown in FIGS. 1 to 7 has a seat surface portion 41 at least in contact with an occupant formed of a soft polyurethane foam, and a vehicle provided with an air distribution channel u. The cushion pad P includes a core pad 2, an upper layer pad 4, and a lower layer pad 6.
The core pad 2 is formed of a non-breathable foam, and a ventilation channel recess 21 is provided on the back surface 2b side. The dent 21 is the back surface 2b of the core pad, occupies the majority of the back surface as shown in FIG. 5, and is dish-shaped in a substantially square shape from the back surface 2b of the core pad toward the front surface 2a. The recess 21 is provided with a plurality (four in this case) of through holes 23 penetrating from the recess bottom 211 to the surface 2a side.
The upper pad 4 is formed of a flexible polyurethane foam, and the seat surface portion 41 is provided on the design surface 4a side (FIG. 4). The inner surface 4b side of the upper pad 4 is joined to the core pad surface 2a, and a plurality (four in this case) of air blowing holes 45 penetrating from the inner surface 4b side to the design surface 4a side are provided. Each air outlet 45 is arranged so as to be electrically connected to each through hole 23.
The lower pad 6 is formed of a non-breathable foam, and the upper surface 6a covers the opening 210 of the recess 21 so as to form the air distribution channel u, and is joined to the back surface 2b of the core pad 2. An air introduction hole 61 penetrates through the lower pad 6 from the lower surface 6b side to the upper surface 6a side. With the joining of the lower pad upper surface 6a and the core pad back surface 2b, the air introduction hole 61 is conducted from the lower surface 6b side of the lower pad 6 to the air distribution channel u.
As shown in FIGS. 3 and 4, the core pad 2 and the upper layer pad 4 have an exposed portion 43 in which the soft polyurethane foam of the upper layer pad 4 passes through the opening 29 and is exposed to the core pad back surface 2 b outside the receiving surface 293. The upper surface pad 293 is received by the surface 293, or the upper layer pad 4 placed on the projecting portion upper end surface 28 of the core pad 2 is wound around the upper end surface 28, and the two are joined and integrated. The lower layer pad 6 and the core pad 2 are joined and integrated via a double-sided tape or an adhesive.

Then, the apparent density of the air-impermeable foam forming the core pad 2 and the lower pad 6 is set to be smaller than the apparent density of the soft polyurethane foam forming the upper pad 4 of the upper pad 4. 6. The desired cushion pad P shown in FIG. 7 is completed. When such a cushion pad P is covered with a skin (not shown), a seat-side seat cushion of the vehicle seat is completed.
Here, it is more preferable that the air-impermeable foam of the core pad 2 and the lower layer pad 6 is a molded article of expanded polypropylene or expanded polystyrene. Foamed polypropylene or Styrofoam molded products, which are low-cost compared to flexible polyurethane foams, are closed cells, and most of the volume is gas, are lightweight and airtight, and air-conditioning air leaks from the air distribution channel u. This is convenient for the core pad 2 and the lower layer pad 6, which must not be provided.

Further, in the cushion pad P of another embodiment shown in FIGS. 8 to 12, on the back surface 2 b side of the core pad 2, the side wall 212 of the recess 21 is carried, and the recess 21 protrudes more toward the back surface 2 b than the recess bottom 211, thereby forming the recess 21. Is formed to extend in a peninsula shape. Due to the extending portion 25 as shown in the figure, a relatively large recess 21 which is recessed in a square on the core material pad back surface 2b side is formed into a groove which forms an air distribution channel u similar to the duct of JP-A-2011-110366. And the extended portion 25 contributes to equal distribution of the air-conditioning air to each air outlet 45. The back surface 25b of the extension portion 25 is formed as a flat surface.
In addition, as shown in FIGS. 8 and 11, the back surface 22 b of the peripheral portion 22 surrounding the recess 21 is formed as a step surface 261 having a constant width recessed stepwise from the back surface 2 b of the core pad 2, and the step surface 261 is formed. And the back surface 25b of the extending portion 25 are formed as a uniform flat surface.

In the cushion pad P of FIGS. 8 to 12, a protrusion 271 is provided in which the core pad 2 projects horizontally outward on the front surface 2 a side, while a retreating portion 272 retracts horizontally inward on the back surface 2 b side. And the upper layer pad 4 covers from the design surface 4 a side to the retreating portion 272. The upper layer pad 4 wraps around the overhang portion 271 to integrally join the core pad 2 and the upper layer pad 4.
The other configuration is the same as the configuration described in (1) Manufacturing method of cushion pad, and description thereof will be omitted. The same reference numerals as those described in (1) indicate the same or corresponding parts.

(3) Effect The cushion pad for a vehicle and the method for manufacturing the cushion pad thus configured include the core pad 2, the upper layer pad 4, and the lower layer pad 6, and the core pad 2 and the lower layer pad 6 are made of a soft polyurethane foam. Since it is formed of a non-breathable foam having a smaller apparent density than the apparent density, the weight is reduced. Nevertheless, since the seating surface portion 41 is provided on the design surface 4a side of the upper pad 4 made of a flexible polyurethane foam, comfort such as cushioning is ensured.

Then, the air distribution channel u, the through hole 23, and the air introduction hole 61 are formed by the lower pad 6 and the core pad 2 of the non-breathable foam, and the air blowing hole 45 is formed by foaming the upper pad 4. Therefore, the temperature-adjusted air can be sent to the seated occupant. When air-conditioning air is sent from an air conditioner (not shown) to the air introduction hole 61, it passes through the plurality of through-holes 23 and each of the air blow-out holes 45 from the air introduction hole 61 through the air distribution channel u to the seat surface 410. Delivers comfortable wind around the buttocks and thighs of seated occupants.
The airflow distribution channel recess 21 is provided on the back surface 2b side of the core pad 2, and a plurality of through holes 23 are formed to penetrate from the concave bottom 211 of the recess 21 to the front surface 2a side. Patent Document 1 discloses a structure in which an opening 210 of the recess 21 is formed so as to form an air inlet hole 61 penetrating from the lower pad lower surface 6b side into the air distribution channel u. Even in a cushion pad having a lower layer made of styrene foam or the like, air can be blown from the seat surface 410 through the air introduction hole 61. By forming the air distribution channel u, the through hole 23, the air blowout hole 45, and the air introduction hole 61, it is possible to blow air with temperature adjusted. When the core pad 2, the upper pad 4, and the lower pad 6 are divided into three parts, the production of the cushion pad P is relatively easy, and the air whose temperature is adjusted is blown to the occupant sitting on the seat using the cushion pad P. it can.
Since the air distribution channel u has a combined configuration of the core pad 2 provided with the recess 21 and the lower layer pad 6, unlike the duct used in JP-A-2011-110366 or the like, it can be manufactured at low cost. By foaming the upper pad 4 with the foam, even if the foaming raw material g enters the recess 21, it can be easily removed, and the yield does not decrease.

  Further, when the non-breathable foam of the core pad 2 and the lower layer pad 6 is a foamed polypropylene or styrofoam molded body, the bulk of the volume becomes gas-impermeable, and the cushion pad P is reduced in weight. And cost reduction can be achieved.

Further, if the extending portion 25 that partitions the recess 21 is formed in the core pad 2 so as to extend in the shape of a peninsula, the lower pad 6 is prevented from being cracked or damaged. Since the lower pad 6 covering the recess 21 is made of non-breathable foam such as foamed polypropylene or Styrofoam, when a slightly large external force is applied to the recess 21 having a substantially square recess, the lower pad 6 is broken or damaged. Or may be done. If there is an extended portion 25 that projects into the recess 21 in a peninsula shape and partitions the recess 21 and the back surface 25b is a flat surface, the external force is received by the extended portion 25 and dispersed, so that the lower layer pad is formed. 6 helps to prevent cracking and damage. When the back surface 25b of the extending portion 25 extending into the recess 21 is formed on a flat surface, when an external force is applied to the lower layer pad 6, even if the lower layer pad 6 is made of foamed polypropylene or styrene foam, which is weak in strength, The lower pad 6 is received on the flat surface to prevent the lower pad 6 from being cracked or damaged.
Furthermore, if the step surface 261 and the back surface 25 of the extending portion 25 are formed as a uniform flat surface, external force can be dispersed and received by the step surface 261 in addition to the extending portion 25, This is more effective in preventing the lower layer pad 6 from being cracked or damaged. Since the external force is more dispersed and received on both the back surface 25 and the step surface 261 of the extending portion 25, the lower pad 6 can be more reliably prevented from being cracked or damaged.

In addition, the pin 92 is inserted through the through hole 23 of the core pad 2, and the tip of the pin 92 is brought into contact with the lower mold surface 81 side to foam-mold the upper layer pad 4 with the core pad 2, thereby forming the through hole 23. The air blowing holes 45 that communicate with the air outlets can be easily formed. In addition, the presence of the pin 92 having a long protrusion length allows the upper pad 4 with the core pad 2 to be attached to the upper mold 9 when the mold is released, so that the mold is opened. And improve workability.
As described above, the vehicle cushion pad P and the method of manufacturing the same achieve the weight reduction and the cost reduction, and the seat surface portion 41 does not impair the conventional comfortable cushioning property, and the air distribution channel is provided inside the cushion pad. u, the air introduction hole 61, the through hole 23, the air outlet hole 45, and the like are provided, so that air whose temperature is adjusted for a seated occupant can be blown. .

  It should be noted that the present invention is not limited to the embodiment described above, and various changes can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, etc. of the cushion pad P, the core pad 2, the recess 21, the through hole 23, the extending portion 25, the upper layer pad 4, the air blowing hole 45, the lower layer pad 6, the foaming mold 7, etc. It can be selected as appropriate.

2 core pad 21 recess 211 recess bottom 210 opening of recess (opening)
212 Side wall of dent 22 Peripheral part surrounding dent (peripheral part)
Reference Signs List 25 extension part 26 step surface 4 upper layer pad 41 seat surface part 45 air outlet 6 lower layer pad 61 air introduction hole 8 lower die 81 lower die surface (mold surface)
9 Upper die 92 pin P Cushion pad g Raw material for flexible polyurethane foam (foaming raw material)
u Distribution channel

Claims (7)

A cushion pad for a vehicle having at least a seat surface portion to which an occupant abuts is made of a soft polyurethane foam, and provided with an air distribution channel,
A core pad made of a non-breathable foam, provided with a ventilation channel recess on the back side, and provided with a plurality of through-holes penetrating from the concave bottom of the recess to the front side,
The seat surface portion is provided on the design surface side, and the inner surface side opposite to the design surface side is bonded to the surface of the core pad, and further penetrates from the inner surface side to the design surface side. An upper layer pad provided with a plurality of air blowing holes, and arranged such that the air blowing holes are respectively connected to the through holes;
Air that is formed of a non-breathable foam, the upper surface of which covers the opening of the recess so as to form an air distribution channel, is bonded to the back surface of the core pad, and further penetrates into the air distribution channel from the lower surface side And a lower pad provided with an introduction hole, wherein the apparent density of the non-breathable foam is lower than the apparent density of the flexible polyurethane foam. The cushion pad for a vehicle according to claim 1, wherein the air-impermeable foam of the core pad and the lower pad is a molded article of expanded polypropylene or expanded polystyrene. On the back side of the core pad, the extension part that bears the side wall of the recess and rises to the back side from the bottom of the recess and that partitions the recess is formed to extend in a peninsula shape, and the back surface of the extension part The vehicle cushion pad according to claim 1 or 2, wherein is formed on a flat surface. The back surface of the peripheral portion surrounding the recess was formed on a step surface recessed in a step shape from the back surface of the core pad, and the step surface and the back surface of the extending portion were formed as a uniform flat surface. The vehicle cushion pad according to claim 3. A method for manufacturing a vehicle cushion pad having an air distribution channel, wherein at least a seat surface portion to which an occupant abuts is made of a soft polyurethane foam,
The apparent density is made of a non-breathable foam smaller than the flexible polyurethane foam, and the airflow channel recess is provided on the back side, and a plurality of through holes are provided from the concave bottom of the recess to the front side. A plurality of pins protruding from the upper mold surface of the foaming mold are inserted into the through holes of the core pad, and the back side of the core pad is brought into contact with the upper mold surface, thereby removing the core pad. Set on the upper mold surface,
Next, the raw material for the flexible polyurethane foam is poured onto the lower mold surface,
Next, the tip of the pin is brought into contact with the lower mold surface side forming the seat surface portion to close the mold,
Subsequently, a seating surface portion is provided on the design surface side, and an upper layer pad of a flexible polyurethane foam having an inner surface side joined to the surface of the core pad is foam-formed,
Thereafter, the mold is released, and thereafter, the lower layer pad is formed of a non-breathable foam having an apparent density smaller than that of the flexible polyurethane foam, and is arranged on the upper surface side of the lower pad having the air introduction hole penetrated from the lower surface side to the upper surface side. A vehicle, wherein the lower layer pad is joined to the back surface of the core pad by covering the opening of the recess so as to form an air flow path, and conducting the air introduction hole into the air distribution flow path. Manufacturing method of cushion pad. The method for manufacturing a vehicle cushion pad according to claim 5, wherein the air-impermeable foam of the core pad and the lower layer pad is a molded article of expanded polypropylene or expanded polystyrene. On the back side of the core pad, the side wall of the dent is supported and raised to the back side from the bottom of the dent to form an extended portion partitioning the dent in a peninsula shape, and the back surface of the extended portion is formed. Are formed on a flat surface, and the back surface of the peripheral portion surrounding the recess is formed as a step surface which is recessed in a step shape from the back surface of the core pad, and the step surface and the back surface of the extending portion are one-sided. 7. The method for manufacturing a vehicle cushion pad according to claim 5, wherein the cushion pad is formed on a flat surface.

Images