JP6859879B2 - Manufacturing method of seat cushion material and foam mold for manufacturing - Google Patents

Description

The present invention relates to a method for manufacturing a seat cushion material constituting a vehicle seat and a foam type for manufacturing the same.

In a vehicle seat, when the seat cover, which is a skin material, is fixed to the surface of the seat pad, which is a cushion material, a cloth or resin hanging member attached to the back surface of the seat cover in a suspension groove recessed in the surface of the seat pad. Some are pulled in and fixed. In the invention disclosed in Patent Document 1, a hanging groove portion extending in the front-rear direction of the seat is provided on the seating surface of the foamed resin seat pad, and a locking member for locking the hanging member is provided on the bottom surface of the hanging groove portion. Is provided. This locking member is attached to the seat pad by being integrally foam-molded in a state of being arranged at a predetermined position in the cavity of the molding mold at the time of foam molding of the seat pad.

Japanese Unexamined Patent Publication No. 2016-88365

In the method for manufacturing a seat pad described in Patent Document 1, a method in which a ridge for forming a suspension groove portion of the seat pad is provided on the cavity surface of the lower mold in the upper and lower molds having a cavity for molding the seat pad is used. Will be done. Then, the seat pad was foam-molded with the locking member temporarily fixed at a predetermined position on the top of the ridge, and the seat pad was integrated in a state where a part of the locking member was embedded in the bottom surface of the hanging groove portion. I got a seat pad. Here, if there is a height difference between the cavity surfaces on both sides of the ridge in the longitudinal direction, the resin raw materials that rise while foaming and hardening from both sides of the ridge do not meet at the top of the ridge and the top of the ridge is on either side. It tended to flow out beyond. In such a case, if the locking member is temporarily fixed to the top of the ridge, a turbulent flow of the resin raw material that rises while foaming and hardening occurs around the locking member, and defects such as voids are likely to occur around the locking member. There was a problem.

The present invention has been devised in view of these points. An object of the present invention is to provide a manufacturing method capable of manufacturing a seat pad provided with a seat cover locking member on the bottom surface of the hanging groove portion while suppressing the occurrence of defects such as voids, and a foam mold for manufacturing the same. ..

The first invention of the present invention is a method for manufacturing a foamed resin seat cushion material having a hanging groove in which a locking member for pulling in and locking a part of the seat cover is arranged at the bottom, and the seat cushion. The molding mold of the material is a lower mold having a lower cavity surface corresponding to the shape of the seat cushion material on the seating surface side and an upper mold having an upper cavity surface corresponding to the shape of the seat cushion material on the side opposite to the seating surface. A ridge having a hanging groove formed on the lower cavity surface of the lower mold and a temporary fixing portion for temporarily fixing the locking member at a predetermined position on the top portion is provided upward. A first surface portion is formed on one side of the lower cavity surface in the longitudinal direction of the ridge, which extends in the horizontal direction or upward as the distance from the ridge increases. On the other side of the cavity surface in the longitudinal direction of the ridge, a second surface portion extending downward as the distance from the ridge is separated is formed, and the portion of the second surface portion corresponding to the temporary fixing portion is formed. Is provided with a vertical wall that is formed in a substantially U shape with the opening side facing the convex shape in a top view and extends upward, and is provided on the first surface portion of the lower mold and the convex side of the vertical wall. It is characterized in that a foamed resin raw material is injected into and on the second surface portion containing the above, and the upper mold is closed and foam-molded.

If the standing wall is not provided, the foamed resin raw material injected into the first surface portion approaches in the direction of the ridges while foaming and solidifying. On the other hand, the foamed resin raw material injected into the second surface portion flows downward and then approaches while foaming and solidifying in the direction of the ridges. Due to the difference in the arrival time of the foamed resin raw material to the ridges, turbulence is generated around the temporarily fixed locking member, and defects such as voids are likely to occur. However, according to the first invention, since the standing wall is provided in the portion corresponding to the temporary fixing portion and the foamed resin raw material is injected onto the second surface portion including the convex side of the standing wall, some of the raw materials are convex on the standing wall. It is held on the strip side and foamed and solidified from there, so that the time lag between the foamed resin raw material injected into the first surface portion and the ridge can be reduced. As a result, it is possible to suppress the occurrence of turbulence around the temporarily fixed locking member and the occurrence of defects such as voids.

In the second invention of the present invention, in the first invention, the height of the standing wall in the vertical direction from the lower cavity surface is about 2/5 of the height of the ridge in the vertical direction from the lower cavity surface. It is characterized in that it is set to.

According to the second invention, since the height in the vertical direction from the lower cavity surface of the vertical wall is smaller than that of the ridges, the depth of the groove-shaped portion formed on the seating surface side of the seat cushion material becomes shallow and opens. It becomes difficult to feel the presence of the groove-shaped portion through the seat cover.

In the third invention of the present invention, in the first invention or the second invention, the ridge is formed in a substantially inverted U shape whose cross section opens downward, and the locking member is temporarily fixed. A flat plate-shaped substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge when temporarily fixed to the portion, and the ridge extending downward from the substrate portion at a predetermined distance. It is characterized by having a pair of engaging protrusions that engage with the temporary fixing portion.

According to the third invention, the locking member can be easily temporarily fixed by engaging a pair of engaging protrusions with the temporary fixing portion. Further, since the substrate portion is arranged in the seat cushion material on the side opposite to the seating surface from the bottom of the suspension groove over a dimension longer than the width in the direction perpendicular to the longitudinal direction of the suspension groove, the locking member is placed in the seat cushion. It can be strongly held by the material.

A fourth aspect of the present invention is a foamed type for manufacturing a foamed resin seat cushion material having a hanging groove in which a locking member for pulling in and locking a part of the seat cover is arranged at the bottom. A lower mold having a lower cavity surface corresponding to the shape of the seat cushion material on the seating surface side and an upper mold having an upper cavity surface corresponding to the shape of the seat cushion material on the side opposite to the seating surface are provided. A ridge having a suspension groove formed on the lower cavity surface of the mold and a temporary fixing portion provided with a temporary fixing portion capable of temporarily fixing the locking member at a predetermined position on the top portion is formed so as to extend upward. On one side of the lower cavity surface in the longitudinal direction of the ridge, a first surface portion extending in the horizontal direction or upward as the distance from the ridge is formed is formed, and the ridge on the lower cavity surface is formed. A second surface portion extending downward as it is separated from the ridge is formed on the other side in the longitudinal direction, and the ridge is viewed from above on the portion of the second surface portion corresponding to the temporary fixing portion. Is provided with a standing wall that is formed in a substantially U shape toward the opening side and extends upward, and is provided on the first surface portion of the lower mold and on the second surface portion including the convex side of the standing wall. And are the sites where the foamed resin raw material is injected.

If the standing wall is not provided, the foamed resin raw material injected into the first surface portion approaches in the direction of the ridges while foaming and solidifying. On the other hand, the foamed resin raw material injected into the second surface portion flows downward and then approaches while foaming and solidifying in the direction of the ridges. Due to the difference in the arrival time of the foamed resin raw material to the ridges, turbulence is generated around the temporarily fixed locking member, and defects such as voids are likely to occur. However, according to the fourth invention, since the standing wall is provided in the portion corresponding to the temporary fixing portion and the foamed resin raw material is injected onto the second surface portion including the convex side of the standing wall, some of the raw materials are convex on the standing wall. It is held on the strip side and foamed and solidified from there, so that the time lag between the foamed resin raw material injected into the first surface portion and the ridge can be reduced. As a result, it is possible to suppress the occurrence of turbulence around the temporarily fixed locking member and the occurrence of defects such as voids.

In the fifth aspect of the present invention, in the fourth invention, the vertical height of the vertical wall from the lower cavity surface is about 2/5 of the vertical height of the ridge from the lower cavity surface. It is characterized in that it is set to.

According to the fifth invention, since the height in the vertical direction from the lower cavity surface of the standing wall is smaller than that of the ridges, the depth of the groove-shaped portion formed on the seating surface side of the seat cushion material becomes shallow and opens. It becomes difficult to feel the presence of the groove-shaped portion through the seat cover.

In the sixth invention of the present invention, in the fourth invention or the fifth invention, the ridge is formed in a substantially inverted U shape whose cross section opens downward, and the locking member is temporarily fixed. A flat plate-shaped substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge when temporarily fixed to the portion, and the temporary fixing of the ridge extending downward from the substrate portion at a predetermined interval. It is characterized by having a pair of engaging protrusions that engage with the portions.

According to the sixth invention, the locking member can be easily temporarily fixed by engaging a pair of engaging protrusions with the temporary fixing portion. Further, since the substrate portion is arranged in the seat cushion material on the side opposite to the seating surface from the bottom of the suspension groove over a dimension longer than the width in the direction perpendicular to the longitudinal direction of the suspension groove, the locking member is placed in the seat cushion. It can be strongly held by the material.

It is a perspective view of the seat cushion using the cushion pad manufactured by one Embodiment of this invention. It is a top view of the cushion pad manufactured by the said embodiment. It is sectional drawing which shows by cutting at the line III-III of FIG. It is a perspective view which shows the state which the suspender is locked to the clip. It is sectional drawing which shows the mold which forms the cushion pad which concerns on the said embodiment. The cross section corresponding to FIG. 3 is shown. The cavity is hollow. It is sectional drawing which shows the mold which forms the cushion pad which concerns on the said embodiment. The cross section corresponding to FIG. 3 is shown. The clip is attached to the lower mold. It is a figure which shows the VII part of FIG. 6 in an enlarged manner. It is sectional drawing which shows the mold which forms the cushion pad which concerns on the said embodiment. The cross section corresponding to FIG. 3 is shown. The state where the foamed resin raw material is injected into the cavity is shown. It is sectional drawing which shows the mold which forms the cushion pad which concerns on the said embodiment. The cross section corresponding to FIG. 3 is shown. It shows a state in which the foamed resin raw material is cured while foaming. It is sectional drawing which shows the mold which forms the cushion pad which concerns on the said embodiment. The cross section corresponding to FIG. 3 is shown. The cushion pad is in a molded state.

Cushion pad 1, which is a seat cushion material manufactured by one embodiment according to the manufacturing method of the present invention, will be described with reference to FIGS. 1 to 4. In each figure, the arrows indicate the directions of the automobile and the cushion pad 1 when the cushion pad 1 is attached to the floor of the automobile. In the following description, the description regarding the direction shall be made with reference to this direction.

FIG. 1 shows a seat cushion SC using the manufacturing method according to the present invention and the cushion pad 1 manufactured by the foam type for manufacturing. The seat cushion SC is for a three-seater bench seat and has a length in the left-right direction that is substantially the same as the width of the passenger compartment. A cushion cover 2 covering the surface of the cushion pad 1 is covered with the cushion pad 1 to form a seat cushion SC. Then, a seat back (not shown) having a similar structure is combined in a state of being erected at the rear end portion of the seat cushion SC and attached to the floor to form a rear seat. Here, the cushion pad 1 and the cushion cover 2 correspond to the "seat cushion material" and the "seat cover" in the claims, respectively.

As shown in FIGS. 1 to 4, the cushion pad 1 has a pair of left and right seat portions 1A and a central seat portion 1B arranged between the left and right seat portions 1A. Further, the cushion pad 1 is formed of urethane foam obtained by foam molding a polyurethane resin, and its density is set to, for ^{example, about 0.045 ± 0.005 g / cm 3.} The cushion pad 1 has a front surface portion 10 having a shape and an area that occupies the entire surface on the seating surface side, and a back surface portion 20 that forms the opposite side to the seating surface. The cushion pad 1 includes a buttocks support portion 11 that supports the buttocks of the seated occupant of the left and right seat portions 1A, and a thigh support portion 12 that supports the thighs of the seated occupant of the left and right seat portions 1A. , Is equipped. Although not shown, the central seat portion 1B is formed thinner than the buttock support portion 11 and the thigh support portion 12, respectively, in both the buttock support portion and the thigh support portion. Further, although not shown, a frame made of a frame-shaped wire is inserted into the front, rear, left and right peripheral edges of the back surface portion 20 of the cushion pad 1. The frame not only functions as a skeleton of the cushion pad 1, but also functions as a mounting member when the cushion pad 1 is mounted on the floor. The surface portion 10 has a pair of vertical grooves 13 extending in the front-rear direction on the left and right sides of the left and right seat portions 1A, a front lateral groove 14 connecting the pair of vertical grooves 13 at a substantially central portion in the front-rear direction, and a rear lateral groove connecting at the rear end portion. 15 is formed. The vertical groove 13, the front horizontal groove 14, and the rear horizontal groove 15 are formed in a substantially U-shape with a cross section opened upward. The back surface portion 20 is provided with a meat stealing hole 21 for weight reduction at a predetermined portion that does not affect the cushioning performance. Here, the front lateral groove 14 corresponds to the "suspended groove" in the claims.

As shown in FIG. 2, two clips 30 are arranged side by side in the front-rear direction at the bottom of the vertical groove 13 corresponding to the left and right side portions of the buttock support portion 11. Further, two clips 30 are arranged side by side in the left-right direction at the bottoms of the front lateral groove 14 and the rear lateral groove 15. That is, 16 clips 30 are arranged in the entire cushion pad 1. Since all 16 clips 30 have the same shape and the same material, as a representative, the clips 30 arranged inside the front lateral groove 14 in the sheet width direction are shown in FIG. As shown in FIG. 4, the clip 30 is an integrally molded resin product and has a plate-shaped substrate portion 31 and two locking portions 32 that rise upward from the substrate portion 31. Here, the clip 30 corresponds to the "locking member" in the claims.

The substrate portion 31 has a substantially rectangular shape with the left-right direction as the longitudinal direction when viewed from above, and is provided with a pair of notches 31a extending so as to be close to each other in the front-rear direction at the central portion in the left-right direction. Further, the substrate portion 31 is provided with four through holes 31b arranged in the left-right direction symmetrically with respect to a center line extending in the longitudinal direction through the center of the substrate portion 31. The notch 31a functions to weaken the torsional resistance of the substrate portion 31, and the through hole 31b increases the mounting strength of the substrate portion 31 to the cushion pad 1 by invading and solidifying the urethane foam resin raw material M forming the cushion pad 1. To work.

Two locking portions 32 are provided at positions symmetrical with respect to the center line extending in the lateral direction through the center of the substrate portion 31. Since the two locking portions 32 have the same shape, the locking portion 32 on the right side will be described as a representative in FIG. The locking portion 32 has a pair of standing wall portions 32a that rise up from the upper surface of the substrate portion 31 facing each other, and a pair of locking claw portions 32b formed on the tip end side of the pair of standing wall portions 32a. The pair of standing wall portions 32a and the pair of locking claw portions 32b have shapes that are symmetrical with respect to the center line extending in the longitudinal direction through the center of the substrate portion 31. The pair of standing wall portions 32a are formed so as to be separated from each other toward the upper tip side from the substrate portion 31, and are elastically deformable in the direction in which the tip side is separated. The pair of locking claw portions 32b are formed so as to extend from the tip end side of the pair of standing wall portions 32a so as to be close to each other. As shown in FIGS. 3 and 4, in the clip 30, the substrate portion 31 is embedded in the cushion pad 1 of the bottom portion 14a of the front lateral groove 14, and the locking portion 32 is the facing surface of the pair of standing wall portions 32a inside the front lateral groove 14. It is installed with the side exposed. The same applies to the rear lateral groove 15 of the substrate portion 31. Further, in the substrate portion 31, standing portions 31c extending upward are provided in front of and behind the locking portion 32. The rising portion 31c functions to limit the distance between the pair of standing wall portions 32a from each other to a predetermined value or less. Here, the pair of standing wall portions 32a and the pair of locking claw portions 32b correspond to the "pair of engaging protrusions" in the claims.

As shown in FIG. 4, the suspenders 40 are attached to the back surface of the cushion cover 2 (the surface opposite to the seating surface) in the portions corresponding to the vertical groove 13, the front lateral groove 14, and the rear lateral groove 15 of the cushion pad 1. There is. The suspender 40 has a non-woven fabric strip 41 whose upper end is attached to the cushion cover 2 and a resin columnar 42 attached to the lower end side (cushion pad 1 side) of the strip 41. doing. The suspenders 40 are integrated by supplying a strip-shaped cloth body 41 having a constant width so that the tip side of the suspenders faces outward while extruding and molding a resin columnar body 42 having a cross section in the shape of a barb. Here, the suspenders 40 correspond to "a part of the seat cover" in the claims.

As shown in FIG. 4, the resin columnar body 42 of the suspenders 40 has a pair of locking claws in two locking portions 32 in which the tip end side of the cross section of the suspender shape is exposed inside the front lateral groove 14 of the cushion pad 1. It is pressed between the tips of the portions 32b. Then, the pair of standing wall portions 32a in the two locking portions 32 are separated from each other in the front-rear direction to receive the resin columnar body 42 below the pair of locking claw portions 32b and return to the original state. As a result, the resin columnar body 42 is attached in a state where the strip-shaped cloth body 41 side is locked by the locking claw portion 32b and the cushion cover 2 is in contact with the surface portion 10 of the cushion pad 1.

As shown in FIGS. 1 to 3, the front portion of the thigh support portion 12 of the cushion pad 1 where the clip 30 is arranged has a substantially U-shaped shape that opens rearward in a top view. A curved groove 16 is formed. As will be described later, the curved groove 16 is formed by the presence of a vertical wall 51d that suppresses the occurrence of defects such as voids around the clip 30 that is integrally molded during foam molding of the cushion pad 1. The length of the open end (rear end) of the curved groove 16 in the left-right direction is formed to be slightly longer than the length in the longitudinal direction of the clip 30. Further, the length in the front-rear direction from the open end (rear end) of the curved groove 16 to the front end opposite to the open end is formed to be slightly shorter than the length in the lateral direction of the clip 30. The shape of the curved groove 16 can be adjusted by the shape of the front lateral groove 14, the set position of the clip 30, and the like. Further, the shape of the cross section of the curved groove 16 is formed in a substantially inverted U shape that opens downward, and the length (depth) of the curved groove 16 in the vertical direction is 2 of the depth of the front lateral groove 14. It is set to about / 5.

The manufacturing method of the cushion pad 1 and the foaming mold for manufacturing will be described with reference to FIGS. 5 to 10. The direction indications in FIGS. 5 to 10 shall be aligned with the direction of the cushion pad 1. As shown in FIG. 5, the urethane foam molding mold 50 for molding the cushion pad 1 is composed of a lower mold 51 and an upper mold 52 that can be opened and closed with respect to the lower mold 51. Both the lower mold 51 and the upper mold 52 are provided with a mold temperature control function for molding urethane foam resin and a lock mechanism (not shown) when the mold is closed. The lower mold 51 is formed with a lower cavity surface 51a having a shape corresponding to the surface portion 10 of the cushion pad 1. The upper die 52 is formed with an upper cavity surface 52a having a shape corresponding to the back surface portion 20 of the cushion pad 1. With the upper mold 52 closed with respect to the lower mold 51, a cavity 53 surrounded by the lower cavity surface 51a and the upper cavity surface 52a is formed between the lower mold 51 and the upper mold 52. On the lower cavity surface 51a, a front convex strip 51b having a shape corresponding to the front lateral groove 14, a rear convex strip 51c having a shape corresponding to the rear lateral groove 15, and a vertical wall 51d having a shape corresponding to the curved groove 16 are formed in the lower cavity. It is formed so as to extend upward substantially perpendicular to the surface 51a. In the lower cavity surface 51a, the portion between the front ridge 51b and the rear ridge 51c is formed as a first surface portion 51a1 that inclines forward and downward toward the front ridge 51b. Further, in the lower cavity surface 51a, the portion from the front convex strip 51b to the front end portion is formed as a second surface portion 51a2 that inclines rearward and upward toward the front convex strip 51b. Further, in the second surface portion 51a2, a portion between the front convex strip 51b and the standing wall 51d is formed as a standing wall upper surface portion 51a21, and the other portion is formed as a standing wall lower surface portion 51a22. Here, the urethane foam molding mold 50 and the front ridge 51b correspond to the "molding mold" and the "convex" in the claims, respectively.

As shown in FIG. 6, the clip 30 is temporarily fixed at a position corresponding to the attachment portion of the clip 30 of the front lateral groove 14 at the upper end portion which is the top of the front convex strip 51b of the lower mold 51. Similarly, the clip 30 is temporarily fixed at a position corresponding to the attachment portion of the clip 30 of the rear lateral groove 15 at the upper end portion which is the top of the rear convex strip 51c of the lower mold 51. Here, as shown in FIG. 7, the constricted portion 51b1 in which the tip end side of the pair of locking claws 32b of the clip 30 is temporarily locked to the upper end side of the front convex strip 51b at the portion where the clip 30 is temporarily fixed. Is provided. The constricted portion 51b1 is provided at four locations in the front convex strip 51b corresponding to the locking portion 32 of the clip 30. The clip 30 temporarily fixed to the constricted portion 51b1 is held so as not to come off in the process of foam molding of the cushion pad 1, and after foam molding, it comes off from the constricted portion 51b1 when the molded cushion pad 1 is removed from the mold. It is configured to be integrally removed from the cushion pad 1. Although the description is omitted, the same applies to the rear ridge 51c, and further to the ridge provided corresponding to the vertical groove 13. Here, the upper end portion of the front convex strip 51b provided with the constricted portion 51b1 corresponds to the "temporary fixing portion" in the claims.

Next, as shown in FIG. 8, the urethane foam resin raw material M is injected onto the lower cavity surface 51a of the lower mold 51 to close the upper mold 52. At this time, the urethane foam resin raw material M1 is injected into the first surface portion 51a1. Further, the urethane foam resin raw material M2 is injected into the vertical wall upper surface portion 51a21 on the second surface portion 51a2. Then, the urethane foam resin raw material M3 is injected into the lower surface portion 51a22 of the vertical wall on the second surface portion 51a2. The polyurethane foam resin raw material M3 may not be injected into the lower surface portion 51a22 of the standing wall, but the urethane foam resin raw material M2 may be injected only into the upper surface portion 51a21 of the standing wall so that a part of the polyurethane foam resin raw material M2 flows forward. Injection of the urethane foam resin raw material M2 into 51a21 is indispensable. Here, the upper surface portion 51a21 of the standing wall corresponds to the "convex side of the standing wall" in the claims. Further, the urethane foam resin raw material M corresponds to the "foamed resin raw material" in the claims.

As shown in FIG. 9, the volume of the urethane foam resin raw material M1 is increased while being foamed and cured on the first surface portion 51a1. Similarly, the urethane foam resin raw material M2 is on the upper surface portion 51a21 of the standing wall, and the urethane foam resin raw material M3 is on the lower surface portion 51a22 of the standing wall, and the volume is increased while foaming and hardening. At this time, the urethane foam resin raw material M1 expands forward and upward from a position close to the front convex strip 51b before and after the front convex strip 51b, and the urethane foam resin raw material M2 expands rearward and upward. At about the same time, they come into contact with each other at the upper part of the clip 30. As a result, the urethane foam resin raw material M1 does not flow over the upper part of the clip 30 toward the front, and turbulence at the peripheral edge of the clip 30 is less likely to occur, so that the occurrence of defects such as voids can be suppressed. If there is no standing wall 51d, the urethane foam resin raw material M2 injected onto the upper surface portion 51a21 of the standing wall flows forward and downward and increases in volume while foaming and curing together with the urethane foam resin raw material M3. .. Then, the clip 30 is delayed in reaching the temporarily fixed portion, and the urethane foam resin raw material M1 flows over the upper portion of the clip 30 toward the front, so that defects such as voids are likely to occur. It should be noted that the reason why the standing wall is not provided behind the rear convex strip 51c is that the occurrence of defects such as voids is unlikely to affect the sitting comfort and the like because the portion is separated from the seating surface. If the occurrence of defects such as voids becomes a problem even in the portion where the clip 30 of the rear ridge 51c is temporarily fixed, take measures to provide a standing wall in a close portion as in the case of the front ridge 51b. Is possible. Needless to say, this measure can be similarly applied to the ridges provided corresponding to the flutes 13.

As shown in FIG. 10, each of the foamed urethane resin raw material M1, the foamed urethane resin raw material M2, and the foamed urethane resin raw material M3 increases in volume while being foamed and cured to fill the cavity 53. At this time, the foamed urethane resin raw material M1, the foamed urethane resin raw material M2, and the foamed urethane resin raw material M3 are fused at their boundaries and integrally cured to form the cushion pad 1 in the cavity 53. A clip 30 and a frame are integrally molded in the cushion pad 1. The cured cushion pad 1 opens the upper mold 52 with respect to the lower mold 51 and removes the mold from the lower mold 51. At this time, in the clip 30, the locking portion 32 is disengaged from the constricted portion 51b1 of the front convex strip 51b in a state where the substrate portion 31 is embedded in the cushion pad 1 of the bottom portion 14a of the front lateral groove 14.

In the above-mentioned manufacturing process and foam molding mold, the following effects are exhibited. The urethane foam resin raw material M1 injected into the first surface portion 51a1 of the lower mold 51 approaches the front front ridge 51b while foaming and solidifying from a position close to the front ridge 51b. Similarly, the urethane foam resin raw material M2 injected into the upper surface portion 51a21 of the vertical wall of the lower mold 51 also approaches the rear front ridge 51b while foaming and solidifying from a position close to the front ridge 51b. The urethane foam resin raw material M1 and the urethane foam resin raw material M2 come into contact with each other at the upper part of the clip 30 at substantially the same time. As a result, it is possible to suppress the occurrence of turbulence around the clip 30 temporarily fixed to the constricted portion 51b1 of the front convex strip 51b and the occurrence of defects such as voids. That is, in the second surface portion 51a2 extending forward and downward as it is separated from the front convex strip 51b, the vertical wall 51d is provided at the portion corresponding to the clip 30 temporarily fixed to the constricted portion 51b1, so that the vertical wall upper surface portion 51a21 The urethane foam resin raw material M2 can be retained. As a result, the urethane foam resin raw material M2 injected into the upper surface portion 51a21 of the standing wall is expanded upward without delaying the downward expansion of the urethane foam resin raw material M1 injected into the first surface portion 51a1, and the front convex strip 51b The difference in arrival time can be reduced.

Further, the height in the vertical direction from the lower cavity surface 51a of the vertical wall 51d is set to 3 to 15 mm, which is about 2/5 of the height in the vertical direction from the lower cavity surface 51a of the front convex strip 51b. As a result, the depth of the curved groove 16 formed in the cushion pad 1 by the standing wall 51d becomes shallow and it becomes difficult to open, so that the presence of the curved groove 16 can be made difficult to be felt through the cushion cover 2. Further, the front ridge 51b is formed in a substantially inverted U shape whose cross section opens downward, and the clip 30 is in a direction perpendicular to the longitudinal direction of the front ridge 51b when temporarily fixed to the constricted portion 51b1. It has a substrate portion 31 that overhangs the surface, a pair of vertical wall portions 32a that engage with the constricted portion 51b1, and a pair of locking claw portions 32b. As a result, the substrate portion 31 is arranged in the cushion pad 1 of the bottom portion 14a of the front lateral groove 14 over a dimension longer than the width in the direction perpendicular to the longitudinal direction of the front lateral groove 14. As a result, the clip 30 can be strongly held by the cushion pad 1.

Although the specific embodiments have been described above, the present invention is not limited to those configurations, and various changes, additions, and deletions can be made without changing the gist of the present invention. For example, the following can be mentioned.

1. 1. In the above embodiment, the shape of the vertical wall 51d is formed in a substantially U shape with the opening side facing the front convex strip 51b in a top view, and extends upward. However, the present invention is not limited to this, and may be formed in a substantially U shape by combining straight lines such as a substantially V shape or a part of a polygon, instead of a smooth curved shape in a top view. Furthermore, the degree of U-shaped curvature includes from shallow to deep.

2. In the above embodiment, the present invention is applied to the cushion pad 1 of the automobile seat, but it may be applied to the back pad of the automobile seat, or the cushion pad or back of the seat mounted on an airplane, a ship, a train, or the like. It may be applied to the pad.

1 Cushion pad (seat cushion material)
2 Cushion cover (seat cover)
14 Front lateral groove (hanging groove)
14a Bottom 30 clip (locking member)
31 Substrate 32a A pair of standing walls (a pair of engaging protrusions)
32b A pair of locking claws (a pair of engaging protrusions)
40 suspenders (part of seat cover)
50 Urethane foam molding mold (molding mold)
51 Lower mold 51a Lower cavity surface 51b Front convex stripe (convex stripe)
51d Standing wall 51a21 Standing wall upper surface 51b1 Constriction 51a1 First surface 51a2 Second surface 52 Upper mold 52a Upper cavity surface 53 Cavity M Polyurethane foam resin raw material M1 Polyurethane foam resin raw material M2 Polyurethane foam resin raw material M3 Polyurethane foam resin raw material SC Seat cushion

Claims (6)

A method for manufacturing a foamed resin seat cushion material having a hanging groove in which a locking member for pulling in and locking a part of the seat cover is arranged at the bottom.
The molding mold of the seat cushion material includes a lower mold having a lower cavity surface corresponding to the shape of the seat cushion material on the seating surface side and an upper cavity surface corresponding to the shape of the seat cushion material on the side opposite to the seating surface. With an upper mold,
The hanging groove is formed on the lower cavity surface of the lower mold, and a ridge provided with a temporary fixing portion capable of temporarily fixing the locking member at a predetermined position on the top is formed so as to extend upward. Has been
On one side of the lower cavity surface in the longitudinal direction of the ridge, a first surface portion extending in the horizontal direction or upward as the distance from the ridge is formed is formed.
On the other side of the lower cavity surface in the longitudinal direction of the ridge, a second surface portion extending downward as it is separated from the ridge is formed.
The portion of the second surface portion corresponding to the temporary fixing portion is provided with a vertical wall formed in a substantially U shape with the opening side facing the convex strip in a top view and extending upward.
A method for producing a seat cushion material, in which a foamed resin raw material is injected into the first surface portion of the lower mold and the second surface portion including the convex side of the standing wall, and the upper mold is closed and foam-molded. In claim 1, the height of the standing wall in the vertical direction from the lower cavity surface is set to about 2/5 of the height of the convex strip in the vertical direction from the lower cavity surface of the seat cushion material. Production method. In claim 1 or 2, the ridge is formed in a substantially inverted U shape whose cross section opens downward.
When the locking member is temporarily fixed to the temporary fixing portion, the locking member has a flat plate-shaped substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the protrusion, and a downward portion of the locking member at a predetermined distance from the substrate portion. method for producing a seat cushion member and a pair of engaging projections for engaging the temporary fixing portion toward extending the convex on. A foam type for manufacturing a foamed resin seat cushion material having a hanging groove arranged at the bottom of a locking member that pulls in and locks a part of the seat cover.
A lower mold having a lower cavity surface corresponding to the shape of the seat cushion material on the seating surface side and an upper mold having an upper cavity surface corresponding to the shape of the seat cushion material on the side opposite to the seating surface are provided.
The hanging groove is formed on the lower cavity surface of the lower mold, and a ridge provided with a temporary fixing portion capable of temporarily fixing the locking member at a predetermined position on the top is formed so as to extend upward. Has been
On one side of the lower cavity surface in the longitudinal direction of the ridge, a first surface portion extending in the horizontal direction or upward as the distance from the ridge is formed is formed.
On the other side of the lower cavity surface in the longitudinal direction of the ridge, a second surface portion extending downward as it is separated from the ridge is formed.
The portion of the second surface portion corresponding to the temporary fixing portion is provided with a vertical wall formed in a substantially U shape with the opening side facing the convex strip in a top view and extending upward.
A foamed mold for manufacturing a seat cushion material, in which the upper part of the first surface of the lower mold and the upper part of the second surface including the convex side of the standing wall are the portions where the foamed resin raw material is injected. In claim 4, the height of the standing wall in the vertical direction from the lower cavity surface is set to about 2/5 of the height of the convex strip in the vertical direction from the lower cavity surface of the seat cushion material. Foam type for manufacturing. In claim 4 or 5, the ridge is formed in a substantially inverted U shape whose cross section opens downward.
When the locking member is temporarily fixed to the temporary fixing portion, the locking member has a flat plate-shaped substrate portion that overhangs in a direction perpendicular to the longitudinal direction of the ridge, and faces downward from the substrate portion at a predetermined interval. A foam mold for manufacturing a seat cushion material having a pair of engaging protrusions extending and engaging with the temporary fixing portion of the convex strip.

Images