JP6709679B2 - Cushion pad for vehicle 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 for manufacturing the same.

A cushion pad that constitutes a seat portion of a seat that is mounted on a vehicle such as an automobile is required to have an appropriate cushioning property. For this reason, polyurethane foam has been exclusively used, but in recent years, there has been a movement to reduce the weight of vehicles. An invention has been proposed in which a non-breathable foam such as a polystyrene foam or a polyethylene foam is used as part of the cushion pad (for example, Patent Documents 1 and 2).

JP-A-9-70330 JP, 2010-259535, A

However, Patent Document 1 describes, in claim 1, "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. It is formed of a body, and the upper and lower layers are integrally joined together. It is a layered different hardness pad for vehicle seats." However, the joining force between the upper and lower layers is weak. In the detailed description, “...the lower layer 3 is molded, and then the upper layer 2 is foam-molded thereon. In the molding process of the upper layer 2, a part of the polyurethane raw solution is impregnated into the polystyrene foam side of the lower layer 3, The upper and lower layers 2 and 3 are firmly joined together by the impregnated portion 4.", but the joint between the two does not become so strong.
Patent Document 2 proposes a "cushion body for a vehicle seat, characterized in that a non-breathable foam made of polyethylene foam is subjected to an easy-adhesion treatment." In the detailed description, “each of the polyethylene foams 12 and 13 has a surface that has been sandpapered beforehand and the coating of the surface foam cells has been broken to roughen the surface.” is there. However, a new work for roughening occurs, and when roughening occurs, the surface-hardened layer is removed and the internal foam layer is exposed, which may cause gas to escape. In addition, there is a possibility that the surface-hardened layer disappears, and the surface becomes brittle.

MEANS TO SOLVE THE PROBLEM This invention solves the said problem, does not increase a work load, lengthens a molding cycle, and prevents a polyurethane foam molding pad laminated on the molding pad of a non-venting foam from peeling off. SUMMARY OF THE INVENTION It is an object of the present invention to provide a vehicle cushion pad and a method for manufacturing the same, which are integrally joined together.

In order to achieve the above object, the gist of the invention according to claim 1 is to provide a horizontal groove in which a groove opening at one end side is exposed on one side surface of the molding pad on the lower surface of the block-shaped molding pad, and a cross with respect to the horizontal groove. -Shaped, T-shaped, or L-shaped transverse grooves are provided, and the horizontal groove, the transverse grooves, and the molding pad are integrally formed as a non-breathable foam molding. A pad, a polyurethane foam molded part that fills the horizontal groove and the transverse groove, and a polyurethane foam molded part that is laminated on the upper surface and the side surface of the core pad are integrally molded to cover the core pad. A polyurethane foam molding part that comprises a surface molding pad, and a polyurethane foam molding part that is laminated on the side surface and a polyurethane foam molding part that is buried in the transverse groove are connected to the polyurethane foam molding part that is buried in the horizontal groove. It is in a vehicle cushion pad. A vehicle cushion pad according to a second aspect of the present invention is the cushion pad for a vehicle according to the first aspect, wherein a vertical groove is provided in a vertical direction on a side surface of the molding pad near a lower end thereof, the vertical groove being integrally formed as a part of the molded body of the core pad. The lower end of the vertical groove is connected to the horizontal groove, and the vertical groove is filled with a polyurethane foam molding portion. A vehicle cushion pad according to a third aspect of the present invention is the cushion pad for a vehicle according to the second aspect, wherein the non-breathable foamed molded article is a molded article of expanded polypropylene or expanded polystyrene, and the upper end of the vertical groove reaches the upper surface side of the molded pad. It is characterized by being A vehicle cushion pad according to a fourth aspect of the present invention is the cushion pad for a vehicle according to the second or third aspect, wherein a plurality of the vertical grooves are provided separately on one side surface of the molding pad, and a horizontal horizontal groove connecting adjacent vertical grooves is provided. The core pad is integrally formed as a part of a molded body, and the vertical groove and the horizontal groove are also filled with a polyurethane foam molded portion.
The gist of the invention according to claim 5 is a horizontal groove in which a groove opening at one end side is exposed on one side surface of the molding pad on the lower surface of the block-shaped molding pad, and a cross shape, a T shape, or a horizontal groove with respect to the horizontal groove. A core material pad provided with a transverse groove arranged in an L shape, and the horizontal groove, the transverse groove and the molding pad are integrally formed as a non-breathable foam molding, is used as a foam mold. Set in a split mold, and then, after the polyurethane foam raw material is injected and the mold is closed, a polyurethane foam molding part for filling the horizontal groove and the transverse groove, and a polyurethane foam molding laminated on the upper surface and the side surface of the core pad. A surface layer molding pad that integrally covers the core material pad with a portion, a polyurethane foam molding portion that is buried in the horizontal groove, a polyurethane foam molding portion that is laminated on the side surface, and a polyurethane foam molding portion that is buried in the transverse groove. And a foaming molding, the method comprising the steps of: forming a cushion pad for a vehicle. A method for manufacturing a vehicle cushion pad according to a sixth aspect of the present invention is the method according to the fifth aspect, wherein a vertical groove is integrally formed as a part of a molded body of the core pad in a vertical direction on a side surface near a lower end of the molded pad. A core pad that is provided and is connected to the horizontal groove at the lower end of the vertical groove is set, the core pad is set in one split mold of a foaming mold, and then the vertical groove is formed together with the horizontal groove and the transverse groove. The surface layer molding pad having a polyurethane foam molding portion to be filled is foam-molded. A method for manufacturing a vehicle cushion pad according to a seventh aspect of the present invention is the method for manufacturing a vehicle cushion pad according to the sixth aspect, wherein the non-breathable foamed molding is a foamed polypropylene or styrofoam molding, and the upper end of the vertical groove is the upper surface side of the molding pad. It is characterized in that the core material pad reaching up to is set in one split mold of a foaming mold. A method for manufacturing a vehicle cushion pad according to an eighth aspect of the present invention is the method for manufacturing a vehicle cushion pad according to the sixth or seventh aspect, wherein a plurality of the vertical grooves are provided on one side surface of the molding pad at a distance from each other, and adjacent vertical grooves are connected to each other in a horizontal direction. The horizontal groove is integrally formed as a part of the molded body of the core pad, and the surface layer molding pad having a polyurethane foam molding portion that fills the lateral groove together with the vertical groove is foam-molded.

A cushion pad for a vehicle and a method for manufacturing the same according to the present invention is a foam molding of a surface layer molding pad, wherein a polyurethane foam molding part is foam-molded together to form a non-air-permeable foam molded article having a groove for mechanical coupling. Since the concave groove related to the core pad is filled and fitted together, the core pad and the surface layer forming pad are hard to separate from each other, and an excellent effect of integration is exhibited.

FIG. 1 is an overall perspective view of a cushion pad with a partially broken surface in one embodiment of the cushion pad and the manufacturing method thereof according to the present invention. It is the elements on larger scale which looked at the cushion pad of FIG. 1 from the lower surface side. It is sectional drawing of the vertical groove in front of FIG. It is sectional drawing of the vertical groove in the back of FIG. It is a partially expanded perspective view of the cushion pad of another aspect replaced with FIG. It is a VI-VI line arrow view of FIG. FIG. 4A is a vertical cross-sectional view of a groove of another aspect which replaces FIG. 3A, and FIG. 4B is a plan view of FIG. It is explanatory sectional drawing which sets the core material pad shown by the VIII-VIII arrow line view of FIG. 5, and injects a foaming raw material into the foaming mold in the mold opening state used for this manufacturing method. FIG. 9 is an explanatory cross-sectional view in which the mold is closed after the foaming raw material of FIG. 8 is injected. It is explanatory sectional drawing which foam-molded the cushion pad.

Hereinafter, a vehicle cushion pad according to the present invention (hereinafter, also simply referred to as "cushion pad") and a method for manufacturing the same will be described in detail. 1 to 10 show one embodiment of a cushion pad and a method for manufacturing the same according to the present invention, FIG. 1 is an overall perspective view of the cushion pad with a partially broken cross section, and FIG. 2 is a bottom view of the cushion pad of FIG. FIG. 3 is a partially enlarged perspective view, FIG. 3 is a sectional view of a vertical groove in the front of FIG. 1, FIG. 4 is a sectional view of a vertical groove in the back of FIG. 1, and FIG. FIG. 6 is a partially enlarged perspective view, FIG. 6 is a view taken along the line VI-VI in FIG. 5, FIG. 7 is a vertical cross-sectional view of a groove of another embodiment in which (a) is replaced with FIG. 3 (a), and (b) is (a). 8 is an explanatory cross-sectional view of setting the core material pad and injecting the foaming raw material into the foaming mold in the mold opening state used in the present manufacturing method, and FIG. 9 is a description of closing the mold after pouring the foaming raw material in FIG. A sectional view and FIG. 10 are explanatory sectional views in which a cushion pad is foam-molded.
In each drawing, essential parts are emphasized for the sake of clarity, and parts not directly related to the present invention are omitted.

(1) Cushion Pad for Vehicle The cushion pad P includes a core pad 1 and a surface layer forming pad 4. The present embodiment is applied to a three-person cushion pad that constitutes a seat portion of a vehicle rear seat as shown in FIG. Like the cushion pad P of FIGS. 1 to 4, it is a cushion pad in which the upper surface 1a and the side surface 1c of the core material pad 1 are covered with the surface layer molding pad 4 of the polyurethane foam molding portion and laminated. In the present invention, the “upper surface” and the “lower surface” refer to the “upper surface” of the paper surface and the “lower surface” hidden in the paper surface of the cushion pad P of FIG. .. In FIG. 1, the vehicle is in a slightly downward direction on the left side of the drawing. The cushion pad P of FIGS. 2 to 7 is drawn upside down in order to make the essential parts of the invention easy to see.

The core material pad 1 is a non-air-permeable foam molded body and is a base body in which the groove 3 is integrally formed with the block-shaped molded pad 2 (FIGS. 1 and 2).
The molding pad 2 is a main portion of a block-shaped non-breathable foamed molded body in which the cushion pad P of the rear seat is made into a block shape and is made smaller by one size. The apparent density of the non-breathable foamed molded product is smaller than that of the surface layer molding pad 4. Here, the non-breathable foamed molded product is a molded product of expanded polypropylene or styrofoam, which has a particularly small apparent density and is very light relative to its size. When the foamed polypropylene or styrofoam is, for example, a molded product of a beaded foamed polypropylene or a beaded foamed styrol, the inside can be a high-foamed layer with an arbitrary magnification and the surface can be a cured film layer. It becomes a non-breathable foamed molded product with a surface film. In the vehicle installed state shown in FIG. 1, the molding pad 2 has a side surface 2c that is a substantially vertical surface, and a lower surface 2b that is around the lower end of the vertical surface forms a horizontal surface.

The horizontal groove 37 and the transverse groove 38 of the concave groove 3 are simultaneously molded by molding of the molding pad 2. On the lower surface 2b of the molding pad 2, a groove on one end side is arranged to be exposed on one side surface 2c of the molding pad 2, and a horizontal groove 37 is arranged in a cross shape, T character shape, or L character shape with respect to the horizontal groove 37. A transverse groove 38 is provided. The horizontal groove 37, the transverse groove 38, and the molding pad 2 are integrally formed as a non-air-permeable foam molding. The groove line of the horizontal groove 37 is arranged substantially at right angles to the one side surface 2c so that the other end of the horizontal groove 37 is away from the one side surface 2c of the molding pad 2 (FIG. 2).

In the present embodiment, the vertical groove 36 is added to the concave groove 3 as a part of the molded body of the core material pad 1 of the air-impermeable foam molded body, and is integrally formed as the molded body of the core material pad 1. The vertical groove 36 is provided on the side surface 2c of the molding pad 2 near the lower end 21. The vertical groove 36 is formed on the side surface 2c of the molding pad, and the horizontal groove 37 and the transverse groove 38 are formed on the lower surface 2b of the molding pad.
The vertical groove 36 is provided on the side surface 2c of the molding pad 2 in the vertical direction near the lower end 21 thereof. The vertical groove 36 extends toward the lower surface 2b of the molding pad, and is connected to the horizontal groove 37 at the lower end 361 of the vertical groove 36. It becomes a bent groove that advances from the vertical groove 36 provided on the molding pad side surface 2c to the molding pad lower surface 2b side through the vertical groove lower end 361. Here, the horizontal groove 37 is a line-shaped groove that is recessed in a concave shape on the lower surface 2b of the molding pad 2. However, the horizontal length may be a little, and the actual horizontal length is short as shown in FIG.

The transverse groove 38 is arranged on the lower surface 2b of the molding pad 2 in a cross shape or a T shape with respect to the horizontal groove 37. In the present embodiment, a horizontal groove 37 extending from the lower end 21 of the side surface of the molding pad 2 toward the center of the lower surface 2b is a transverse groove 38 intersecting in a T shape at the tip. The groove bottom 38e of the transverse groove 38 may have the same depth as the groove bottom 37e of the horizontal groove 37, but it is more preferably set deeper than the groove bottom 37e of the horizontal groove 37 as shown in FIG. This is because if the transverse groove 38 becomes deeper, the transverse groove filling portion 48 (described later in detail) of the surface layer forming pad 4 that covers the core material pad 1 is deeply buried, and the bonding force between the core material pad 1 and the surface layer forming pad 4 increases. ..

FIG. 7 illustrates a concave groove 3 of another mode, which is an alternative to the concave groove 3 of FIGS. 1 to 4, in which a horizontal groove 37 and a transverse groove 38 are arranged in a cross shape on the lower surface 2b of the molding pad 2. ing. The concave groove 3 on the back side of the paper surface of FIG. 1, that is, the concave groove 3 of FIG. 4, extends from the lower end 361 of the vertical groove 36 to the horizontal groove 37 on the core material pad lower surface 1b side to the position of the transverse groove 38. However, the horizontal groove 37 of FIG. 7 has a protruding groove 37A that traverses the transverse groove 38 and further extends toward the center of the lower surface.

The surface layer molding pad 4 is a cushion provided with a polyurethane foam molded part that is embedded in the vertical groove 36, the horizontal groove 37, and the transverse groove 38, and a polyurethane foam molded part that is laminated on the upper surface 1a and the side surface 1c of the core pad. It is a surface layer side pad of the pad P. As described above, the vertical groove 36, the horizontal groove 37, and the transverse groove 38 are formed on the upper surface 1a and the side surface 1c of the core pad together with the molding pad 2 of the core pad 1. A surface layer molding pad 4 in which a polyurethane foam molding part buried in the vertical groove 36, the horizontal groove 37, and the transverse groove 38 and a polyurethane foam molding part laminated on the upper surface 1a and the side surface 1c of the core pad are integrated, Cover the core pad 1. On the upper surface 1a and the side surface 1c of the core pad, the upper surface layer portion 41 and the side surface layer portion 42 of the polyurethane foam molding portion of the surface layer molding pad 4 forming the outer shape of the cushion pad P are laminated. The vertical groove 36, the horizontal groove 37, and the transverse groove 38 have the vertical groove filling portion 46, the horizontal groove filling portion 47, and the transverse groove filling portion 48 of the polyurethane foam molding portion related to the surface layer molding pad 4 in the respective groove shapes. Buried in a mating form.
Also for the horizontal groove 37 having the protruding groove 37A in FIG. 7, the horizontal groove 37 including the protruding groove 37A is filled with the horizontal groove filling portion 47 of the polyurethane foam molding portion and laminated on the upper surface 1a and the side surface 1c of the core pad. The surface layer forming pad 4 is provided with the upper surface layer portion 41 and the side surface layer portion 42.

FIGS. 5 and 6 show a cushion pad P of another form which replaces the cushion pad P of FIGS. 1 to 4, and shows a cushion pad further provided with a lateral groove 39. The lateral groove 39 also becomes a part of the molded body of the core material pad 1 of the air-impermeable foam. On one side surface 2c of the molding pad 2, a plurality of vertical grooves 36 are provided apart from each other, and a horizontal horizontal groove 39 connecting the adjacent vertical grooves 36 is provided, and the horizontal groove 39 is also polyurethane foamed together with the vertical groove 36. Filled with molding. In the cushion pad P of FIG. 5, two vertical grooves 36 are provided, and three horizontal grooves 39 connecting both vertical grooves 36 are provided separately from each other. These are the vertical groove filling portion 46 and the horizontal groove filling of the polyurethane foam molding portion. Filled with part 49.
As described above, the vertical groove 36, the horizontal groove 37, the horizontal groove 38, and the horizontal groove 39 are formed on the upper surface 1a and the side surface 1c of the core pad of FIG. The upper surface layer portion 41 and the side surface layer portion 42 of the polyurethane foam molded portion forming the outer shape of the cushion pad P are laminated on the upper surface 1a and the side surface 1c of the core pad. The surface layer molding pad 4 is foam-molded so that the polyurethane foam molding portion fills the 36, the horizontal groove 37, the transverse groove 38, and the lateral groove 39.

Regarding the integration of the core material pad 1 and the surface layer molding pad 4, it is sufficient to provide the horizontal groove 37 and the transverse groove 38 as the concave groove 3. Even if an external force as indicated by an arrow in FIG. 3B for peeling the surface layer molding pad 4 is applied to the lower edge portion of the surface layer molding pad 4, a horizontal groove filling portion 47 that is buried in the horizontal groove 37 is formed on the side of the surface layer molding pad 4. This is because the surface layer portion 42 and the transverse groove filling portion 48 buried in the transverse groove 38 can be connected to each other and can function as a stopper that the transverse groove filling portion 48 prevents. The portion of the transverse groove filling portion 48 protruding outwardly beyond the horizontal groove 37 hits the groove wall 38f of the transverse groove 38, and is finished into a desired cushion pad P that prevents the surface layer molding pad 4 from being peeled off. By covering the cushion pad with a skin (not shown), a seat cushion on the seat of the rear seat of the vehicle is completed.

Here, it is more preferable if the groove 3 of the cushion pad P is provided with the vertical groove 36. The presence of the vertical groove filling portion 46 that is embedded in the vertical groove 36 that is vertically longer than the groove depth of the horizontal groove 37 can strengthen the connection between the horizontal groove filling portion 47 and the side surface layer portion 42 of the surface layer forming pad 4. Further, it is more preferable that the upper end 362 of the vertical groove 36 extends to the upper surface 2a side of the molding pad 2 like the vertical groove 36 on the far side of the paper surface of FIG. This is because the vertical groove 36 also serves as a degassing passage for the foaming gas when foaming the surface layer molding pad 4. The thickness t of the surface layer forming pad 4 laminated and formed on the core material pad side surface 1c is smaller than the thickness of the upper surface layer portion 41. In a region where the thickness is thin, a problem that excess foaming gas is blocked during foam molding of the core pad 1 is likely to occur, but this can be solved.
In the figure, reference numeral P1 is a seat portion, reference numeral P2 is a connection portion with a backrest, reference numeral 4a is a surface of a surface layer forming pad, and reference numeral 43 is a side surface layer portion 42 extending beyond the lower surface of the core material pad 1. A projecting portion, reference numeral 10 is an opening of the core material pad 1, reference numeral 40 is an opening of the surface layer forming pad 4, and seat belts are attached to these overlapping openings 10 and 40.

(2) Method for manufacturing vehicle cushion pad In the method for manufacturing a vehicle cushion pad, the core material pad 1 and the foaming mold 7 are used, and after the core material pad 1 is set in the foaming mold 7, the foaming raw material g is injected and After closing the mold, a cushion pad P as shown in FIG. 10 is formed. Prior to manufacturing, the core material pad 1 and the foaming mold 7 are prepared.

As described above, the core pad 1 is arranged on the lower surface 2b of the molding pad in the form of a horizontal groove 37 having a groove opening at one end exposed on one side surface 2c of the molding pad 2 and in a cross shape or a T-shape with respect to the horizontal groove 37. Is a base body for the cushion pad P in which the molded pad 2, the horizontal groove 37 and the horizontal groove 38 are integrally formed as a molded body of a non-breathable foam. It is a block-shaped non-breathable foamed molded product, which is pre-molded prior to manufacturing the cushion pad. The core pad 1 here is for a cushion pad P as shown in FIGS. 5 and 10, and is provided with a vertical groove 36, a horizontal groove 37, a transverse groove 38, and a horizontal groove 39.

The foaming mold 7 used in the method for manufacturing the cushion pad is a split mold as shown in FIGS. 8 to 10, and includes an upper mold 9 (one split mold) and a lower mold 8 (another split mold). When the mold is closed from FIG. 8 to FIG. 9 using the hinge 71 as a fulcrum, the cavity surface C of the cushion pad P is formed by the die surface 81 of the lower die 8 and the die surface 91 of the upper die 9 which are substantially flat. .. In the present manufacturing method shown in FIGS. 8 to 10, the design surface side of the cushion pad P is molded by the lower mold surface 81, and the back surface side of the cushion pad P is molded by the upper mold surface 91. The cushion pad P shown in FIG. 1 is molded in an upside down state.

Using the core material pad 1 and the foaming mold 7, the cushion pad P of FIG. 5 is manufactured as follows, for example.
First, the foaming mold 7 is opened. Next, the core material pad 1 is set on the upper mold 9 in the mold open state. The core pad 1 is set so that the core pad lower surface 1b is brought into contact with the upper mold surface 91 (FIG. 8).

After that, polyurethane foam raw material g (hereinafter, also simply referred to as “foaming raw material”) is injected and the mold is closed. With the mold open state of FIG. 8, a predetermined amount of the foaming raw material g is injected into the lower mold surface 81 using an injection hose NL or the like.
Then, the upper mold 9 is operated to close the mold (FIG. 9). By closing the upper die 9 and the lower die 8, the cushion pad cavity C in which the core pad 1 is insert-set is formed. Although the mold is closed after the foaming raw material g is injected in the present embodiment, the foaming raw material g can be injected after the mold is closed.

After the mold is closed, the main process is foam molding. The mold closed state of FIG. 9 is maintained for a predetermined time, the vertical groove 36, the horizontal groove 37, the transverse groove 38, and the horizontal groove 39 shown in FIG. 5 are filled with a polyurethane foam molding portion, and the upper surface 1a and the side surface of the core material pad. A cushion pad P is produced by foam-molding a surface layer molding pad 4 having a polyurethane foam molding portion laminated on 1c.
In the foam molding of the surface layer molding pad 4, the polyurethane foam material g enters the vertical groove 36, the horizontal groove 37, the transverse groove 38, and the lateral groove 39 to fill and form the polyurethane foam molded portion, and the upper surface 1a and the side surface of the core pad. The surface layer molding pad 4 is foam-molded so that the upper surface layer portion 41 and the side surface layer portion 42 of the polyurethane foaming raw material g are laminated on 1c. On the core material pad upper surface 1a and the core material pad side surface 1c, the upper surface layer portion 41 and the side surface layer portion 42 on the design surface side of the cushion pad P are laminated, and the vertical groove 36, the horizontal groove 37, the transverse groove 38, And the lateral groove 39 becomes the surface layer molding pad 4 in which the vertical groove filling portion 46, the horizontal groove filling portion 47, the transverse groove filling portion 48, and the lateral groove filling portion 49 of the polyurethane foam molding portion are filled (FIGS. 4 to 6). The surface layer forming pad 4 which is integrated with the inserted core material pad 1 in such a manner that the horizontal groove filling portion 47, the transverse groove filling portion 48 and the like are fitted into the respective groove shapes such as the horizontal groove 37 and the transverse groove 38. Is foam-molded. The lower surface 1b of the core pad is exposed as shown.

In the mold closed state, one end side slot of the horizontal groove 37 communicates with the cavity C forming the lateral surface layer portion 42. In foam molding of the surface layer molding pad 4, the foam raw material g is fed from the slot to the horizontal groove 37 and the transverse groove. Infiltrate into 38. If the vertical groove 36 is provided, the circumference of the horizontal groove 37 into which the foaming raw material g penetrates is widened, and the horizontal groove filling portion 47 and the transverse groove filling portion 48 of the polyurethane foam molding portion can be favorably molded. Further, when the upper end 362 of the vertical groove 36 reaches the upper surface 2a side of the molding pad 2, the surface layer molding pad 4 is molded well and the yield of the cushion pad P is improved. Explaining with reference to FIG. 4, the thickness of the lateral surface layer portion 42 of the surface layer molding pad 4 is set to be thin. Therefore, during foam molding, it is difficult for the foam raw material g to flow toward the overhanging portion 43 located at the tip of the lateral surface layer portion 42, and during foam molding, the foam raw material g is cured without foaming at this portion. In addition, excessive foaming gas may not be able to escape, resulting in defective molding.
However, when the upper end 362 of the vertical groove 36 reaches the upper surface 2a side of the molding pad 2, a new passage for the groove depth h can be formed (a in FIG. 4) to improve the passage of the foaming raw material g and the surplus foaming gas. To do. In the foaming process, the foaming raw material g smoothly rises and infiltrates through the vertical groove 36 to the points of the horizontal groove 37 and the transverse groove 38 as shown by the arrow in FIG. Although illustration is omitted, in the process in which the foaming raw material g rises in the vertical groove 36, the foaming raw material g also flows toward the lateral groove 39.

As described above, the vertical groove filling portion 46, the horizontal groove filling portion 47, and the horizontal groove filling portion 48 in which the foaming raw material g is securely filled and fitted into the respective grooves of the vertical groove 36, the horizontal groove 37, the transverse groove 38, and the transverse groove 39. , And the lateral groove filling portion 49, and the upper surface layer portion 41 and the side surface layer portion 42 are integrally foam-molded. When the foam molding of the surface layer molding pad 4 is completed and the mold is removed, a desired cushion pad P in which the core material pad 1 is embedded and integrated is obtained.
In the drawing, reference numerals 89 and 99 denote mold matching surfaces, and reference numeral 811 denotes a recess for forming a backrest connection portion. The rest of the configuration is the same as the description of (1) cushion pad, and is omitted.

(3) Effects The cushion pad for a vehicle and the method for manufacturing the same configured as described above is a cushion pad P which is a non-breathable foam and has a polyurethane foam molding part laminated on a light core pad 1, so that the cushion pad is lightweight. Be promoted. When the polystyrene pad or the polyethylene foam is used for the core pad 1, the core pad 1 can be made very light, and the weight of the cushion pad P can be further reduced.

Further, the horizontal groove 37 and the transverse groove 38 are formed in the core material pad 1, and the horizontal groove filling portion 47 and the transverse groove filling portion 48 of the polyurethane foam molding portion which are buried in the horizontal groove 37 and the transverse groove 38 in the surface layer molding pad 4. With the provision, even if the back surface 4b of the surface layer molding pad and the core pad 1 are not adhered, they can be mechanically combined and integrated. That is, since the groove opening on one end side of the horizontal groove 37 is exposed on the one side surface 2c of the molding pad 2 on the lower surface 2b of the molding pad 2, one end side of the horizontal groove filling portion 47 is formed on the one surface side by the foam molding of the surface layer molding pad 4. It is joined to the lower edge portion of the lateral surface layer portion 42 of the pad. Then, the transverse groove filling portion 48, which is connected to the horizontal groove filling portion 47, blocks the external force for peeling off the surface layer molding pad 4. If the groove bottom 38e of the transverse groove 38 is made deeper than the groove bottom 37e of the horizontal groove 37 and the transverse groove filling portion 48 is buried deeply, the surface layer molding pad 4 is more strongly prevented from being peeled from the core material pad 1. Can be stopped. The bonding force between the core material pad 1 and the surface layer molding pad 4 is further increased. When the horizontal groove filling portion 47 and the transverse groove filling portion 48 are provided at necessary positions in the peripheral portion of the molding pad lower surface 2b at appropriate intervals, the core material pad 1 and the surface layer molding pad 4 covering the core material pad 1 are integrated. Become rock solid.
The integration of the core material pad 1 and the surface layer molding pad 4 does not require roughening the surface of the core material pad 1 as in Patent Document 2. In the foam molding of the surface layer molding pad 4, the horizontal groove filling portion 47, the transverse groove filling portion 48, and the like that fit into the concave groove 3 are simultaneously molded by the foam molding of the surface layer molding pad 4, so that the cushion pad P is easily manufactured. It has become. In addition, the mechanical groove of the horizontal groove filling portion 47, the transverse groove filling portion 48, and the like, which are fitted together, ensures robustness.

In the cushion pad P, the lower edge portion of the lateral surface layer portion 42 of the surface layer molding pad 4 extends as shown in FIG. Since there are many cases in which the projecting portion 43 projects downward, the projecting portion 43 is easily flipped by an external force. This is prevented by the horizontal groove filling portion 47 and the transverse groove filling portion 48.
Even when an external force indicated by an arrow shown in FIG. 3B is applied to the overhanging portion 43, the horizontal groove filling portion 47 connected to the overhanging portion 43 transmits to the transverse groove filling portion 48, and the transverse groove filling portion 48 receives an external force. Resist against. The transverse groove filling portion 48 hits the groove wall 38f of the transverse groove 38 protruding outwardly beyond the horizontal groove 37 to block the resistance, and the protruding portion 43 does not separate from the core pad 1 and the core pad 1 The integration of the surface layer molding pad 4 is maintained.
Further, since the surface layer molding pad 4 autonomously creates the horizontal groove filling portion 47 and the transverse groove filling portion 48 by its own foam molding, it does not increase the work load.

Further, the horizontal groove 37 and the transverse groove 38 in which the horizontal groove filling portion 47 and the transverse groove filling portion 48 are filled are integrally formed with the molding pad 2 as an air-impermeable foamed molded body, and a surface coating layer (skin) is formed on the molded body. When the layer is formed, there is no fear that the internal foam layer is exposed and gas is released or becomes brittle.

Further, when the core material pad 1 is provided with the vertical groove 36 and the surface layer forming pad 4 is provided with the vertical groove filling portion 46, the vertical groove filling portion 46 is coupled to the horizontal groove filling portion 47 to form the horizontal groove filling portion 47. The binding force with the lateral surface layer portion 42 increases. When the upper end 362 of the vertical groove 36 reaches the upper surface 2a side of the molding pad 2, the foaming raw material g smoothly rises in the cavity C for forming the side surface layer portion 42 during foam molding by using the vertical groove 36. Advances and smooth degassing of excess foaming gas is performed. This helps to improve the yield of the cushion pad P.
In addition, when the core material pad 1 is provided with the lateral groove 39 and the surface layer forming pad 4 is provided with the lateral groove filling portion 49, the lateral surface layer portion 42 tends to shift upward or downward with respect to the core material pad 1 in FIG. Also, the lateral groove filling portion 49 fitted in the lateral groove 39 prevents and prevents this. With respect to the core pad 1, the lateral surface layer portion 42 is prevented from being displaced not only in the horizontal direction of FIG. 3B but also in the vertical direction, so that the quality is further improved.
As described above, the vehicle cushion pad and the method for manufacturing the same exhibit the various excellent effects described above, and are extremely useful.

The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. In this embodiment, the transverse grooves 38 project outward from both sides of the horizontal groove 37 and are arranged in a cross shape or a T-shape with respect to the horizontal groove 37. You may arrange|position in what is called an L character shape. The shape, size, number, material and the like of the core pad 1, the molding pad 2, the concave groove 3, the surface molding pad 4, the foaming mold 7 and the like can be appropriately selected according to the application.

1 Core material pad 1a Upper surface (upper surface of core material pad)
1c side (the side of the core material pad)
2 Molding pad 2b Lower surface (lower surface of molding pad)
2c Side (side of molding pad)
36 Vertical Groove 37 Horizontal Groove 38 Transverse Groove 39 Horizontal Groove 4 Surface Molding Pad 7 Foaming Mold 9 Upper Mold g Polyurethane Foaming Raw Material (Foaming Raw Material)

Claims (8)

On the lower surface of the block-shaped molding pad, a horizontal groove having a groove opening on one end side exposed on one side surface of the molding pad and a transverse groove arranged in a cross shape, a T-character shape, or an L-character shape with respect to the horizontal groove are provided. A core pad that is provided and in which the horizontal groove, the transverse groove, and the molding pad are integrally formed as a non-breathable foam molding;
A surface layer molding pad that covers the core pad by integrally molding a polyurethane foam molding part that fills the horizontal groove and the transverse groove, and a polyurethane foam molding part that is laminated on the upper surface and the side surface of the core pad. And ,
A cushion pad for a vehicle , wherein a polyurethane foam molded portion laminated on the side surface and a polyurethane foam molded portion buried in the transverse groove are connected to each other by a polyurethane foam molded portion buried in the horizontal groove . A vertical groove integrally formed as a part of a molded body of the core pad is provided in a vertical direction on a side surface near the lower end of the molding pad, and the lower end of the vertical groove is connected to the horizontal groove. The vehicle seat pad according to claim 1, wherein the groove is filled with a polyurethane foam molding portion. The cushion pad for a vehicle according to claim 2, wherein the non-air-permeable foamed molded product is a molded product of expanded polypropylene or styrofoam, and the upper end of the vertical groove reaches the upper surface side of the molded pad. On one side surface of the forming pad, a plurality of the vertical grooves are provided separately from each other, and horizontal horizontal grooves connecting adjacent vertical grooves are integrally formed as a part of the molded body of the core pad, and The cushion pad for a vehicle according to claim 2 or 3, wherein the horizontal groove and the horizontal groove are also filled with a polyurethane foam molded portion. On the lower surface of the block-shaped molding pad, a horizontal groove having a groove opening on one end side exposed on one side surface of the molding pad and a transverse groove arranged in a cross shape, a T-character shape, or an L-character shape with respect to the horizontal groove are provided. A core pad, which is provided and in which the horizontal groove, the transverse groove, and the molding pad are integrally formed as a non-breathable foam molding, is set in one split mold of a foam mold, and then polyurethane foam is formed. After the raw material is injected and the mold is closed, the polyurethane foam molded part that fills the horizontal groove and the transverse groove and the polyurethane foam molded part that is laminated on the upper surface and the side surface of the core material pad are integrated to form the core material pad. The surface layer molding pad for covering the surface layer molding pad is foam-molded by connecting the polyurethane foam-molded portion that is laminated on the side surface and the polyurethane foam-molded portion that is buried in the transverse groove with the polyurethane foam-molded portion that is buried in the horizontal groove. And a method for manufacturing a vehicle cushion pad. A vertical groove integrally formed as a part of the molded body of the core pad is provided in a vertical direction on a side surface near the lower end of the molding pad, and the lower end of the vertical groove is connected to the horizontal groove as a core pad. 6. The core material pad is set in one split mold of a foaming mold, and then the surface layer molding pad having a polyurethane foam molding part for filling the vertical groove together with the horizontal groove and the transverse groove is foam-molded. A method for manufacturing the above-described vehicle cushion pad. The non-breathable foamed molded body is a molded body of foamed polypropylene or styrofoam, and the core material pad where the upper end of the vertical groove reaches the upper surface side of the molding pad is set in one split mold of a foaming mold. Item 7. A method for manufacturing a vehicle cushion pad according to Item 6. On one side surface of the molding pad, a plurality of the vertical grooves are provided separately, and horizontal horizontal grooves connecting adjacent vertical grooves are integrally formed as a part of the molded body of the core pad. The method for manufacturing a cushion pad for a vehicle according to claim 6 or 7, wherein the surface layer molding pad having a polyurethane foam molding portion that fills the groove as well as the groove is foam-molded.

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