JP7038566B2 - Seat pad and its manufacturing method - Google Patents

Description

The present invention relates to a seat pad and a method for manufacturing the same.

The seat pad disclosed in Patent Document 1 has a structure in which a pad portion made of a foam of polyurethane resin covers a base portion made of a bead foam molded body of polystyrene resin from the front side. Such a seat pad is manufactured by foam-molding the pad portion in the foam-molding mold with the base portion set in the upper mold of the foam-molding mold.

Japanese Unexamined Patent Publication No. 9-70330 (paragraph [0008], FIG. 1)

By the way, in the seat pad as described above, since the base portion is made of a material having poor air permeability, when the polyurethane resin is foamed, gas such as foaming gas or air in the foam molding mold becomes the base portion and the pad portion. A lack of meat may be formed in the seat pad due to accumulation in the boundary portion of the seat pad, and as a result, a problem that the sitting comfort may be deteriorated may occur. On the other hand, it is conceivable to provide a gas vent hole penetrating the base portion, but in this case, the polyurethane resin leaking to the outside from the gas vent hole rubs against the member around the seat pad, and an abnormal noise is generated. Another problem could occur. Therefore, there is a problem that the productivity of the conventional seat pad is low.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a seat pad capable of improving productivity and a method for manufacturing the same.

The invention of claim 1 made in order to achieve the above object is a seat pad in which a base portion made of a bead foam molded body is integrally fixed to the back side of a pad portion made of a soft thermosetting resin foam. It has a through hole that penetrates the base portion in the front and back directions and a porous body that has air permeability and is packed in the through hole, and the porous body has the pad portion. It is a seat pad impregnated and cured with the raw material of the thermosetting resin foam constituting the above.

According to the second aspect of the present invention, the through hole is provided with a stepped portion that expands the through hole stepwise from the front side to the back side of the base portion, and the porous body is the through hole. The seat pad according to claim 1, which is housed in a portion behind the step portion.

The invention according to claim 3 is the seat pad according to claim 1 or 2, wherein the porous body is composed of a foam having an open cell structure.

In the invention of claim 4, the raw material of the soft thermosetting resin foam is foam-cured in the foam-molded mold in a state where the base portion made of the bead foam-molded body is set in the upper mold of the foam-molded mold. A method for manufacturing a seat pad for forming a pad portion that covers the base portion from the front side, wherein a through hole penetrating in the front and back directions is formed in the base portion, and prior to the formation of the pad portion. It is a method of manufacturing a seat pad including filling the through hole with a porous body having breathability.

The invention according to claim 5 is the method for manufacturing a seat pad according to claim 4, wherein when the pad portion is formed, the raw material of the thermosetting resin foam is impregnated and cured in the porous body.

In the invention of claim 6, the through hole is formed with a stepped portion that expands the through hole stepwise from the front side to the back side of the base portion, and the porous body is formed in the through hole. The method for manufacturing a seat pad according to claim 5, wherein the seat pad is housed in a portion behind the step portion.

The invention according to claim 7 is the method for manufacturing a seat pad according to any one of claims 4 to 6, wherein a foam having an open cell structure is used as the porous body.

[Inventions of Claims 1, 4 and 5]
In the present invention, a porous body having air permeability is packed in a through hole penetrating the base portion made of a bead foam molded product in the front and back directions. As a result, when the raw material of the thermosetting resin foam is foamed and cured in the foam molding mold with the base portion set in the upper mold of the foam molding mold to form the pad portion, the thermosetting resin foam is formed. The gas accumulated between the base portion and the base portion can be discharged to the outside through the through hole, and it is possible to suppress the occurrence of a missing portion in the seat pad. Further, since the porous body is packed in the through hole, it is possible to prevent the thermosetting resin from leaking to the outside from the through hole when the pad portion is formed. As described above, according to the present invention, it is possible to suppress the occurrence of defects in the seat pad and improve the productivity of the seat pad.

Moreover, in the inventions of claims 1 and 5, the raw material of the thermosetting resin foam constituting the pad portion impregnates the porous body. Therefore, during the foam molding of the pad portion, the foaming expansion of the raw material of the thermosetting resin foam that has invaded while foaming into the through hole is suppressed in the porous body.

[Inventions of Claims 2 and 6]
In the present invention, the raw material of the thermosetting resin foam constituting the pad portion is impregnated and cured in the porous body. Further, the porous body is accommodated on the back side (that is, the side opposite to the pad portion) of the stepped portion of the through hole. Therefore, the porous body is caught in the stepped portion of the through hole, the pad portion is prevented from coming off with respect to the base portion, and the stability of fixing the pad portion to the base portion can be further enhanced.

[Invention of claims 3 and 7]
According to the present invention, it becomes easy to adjust the size of air bubbles in the foam as a porous body at the time of manufacturing the porous body, and the porous body is made into a thermosetting resin foam while having air permeability. It becomes easy to make the raw material of the above-mentioned material difficult to foam and expand. Further, since the porous body is a foam, it becomes easy to fill the through holes with the porous body without gaps by utilizing elasticity.

(A) perspective view of the seat, (B) side sectional view of the seat pad Enlarged side sectional view around the through hole of the seat pad Side sectional view of the base portion and the porous body packed in the through hole Side cross-sectional view of the foam molding mold that has been opened and the base is set. Side cross-sectional view of the molded foam mold closed and the base (A) side sectional view around the through hole of the base portion during foam molding, (B) side sectional view of the raw material of the thermosetting resin foam that has entered while foaming into the through hole, (C) thermosetting property. Side sectional view of the porous body impregnated with the raw material of the resin foam Side sectional view of the pad portion formed in the foam molding mold.

As shown in FIGS. 1A and 1B, the seat pad 10 according to the present embodiment is applied to a cushion pad used for a seating portion 91 of a seat 90 of a vehicle or the like. The seating portion 91 covers the seat pad 10 with the cover 93. In the following, in the seat pad 10, the seated side is referred to as the front side, and the side opposite to the seated person is referred to as the back side as appropriate.

As shown in FIG. 1 (B), the seat pad 10 has a base portion 20 integrally fixed to the back side of the pad portion 11. The pad portion 11 is made of a soft thermosetting resin foam, and the base portion 20 is made of a bead foam molded body. Examples of the thermosetting resin foam constituting the pad portion 11 include a polyurethane-based resin foam. Examples of the bead foam molded body constituting the base portion 20 include a bead foam molded body made of a polystyrene resin, a bead foam molded body made of a polyolefin resin (polyethylene resin, polypropylene resin, etc.) and the like.

The base portion 20 is formed with a through hole 21 penetrating in the front and back directions. Specifically, the base portion 20 has a curved concave surface 26 on the front surface facing the pad portion 11, and the through hole 21 is open to the bottom portion 27 of the curved concave surface 26 of the base portion 20. The back side surface of the pad portion 11 has a shape corresponding to the front side surface of the base portion 20, and has a bulging portion 19 corresponding to the curved concave surface 26.

As shown in FIG. 2, the through hole 21 is provided with a step portion 24 that expands the through hole 21 in a stepped manner from the front side to the back side of the base portion 20, and the front side portion is a small hole from the step portion 24. In addition to being a portion 22, a portion behind the step portion 24 is a large hole portion 23.

The through hole 21 is filled with the porous body 30. Specifically, the porous body 30 is arranged in the large hole portion 23. Further, the porous body 30 is made of a foam having an open cell structure, and is made of, for example, a urethane slab. In this embodiment, the porous body 30 has substantially the same size as the large pore portion 23.

Here, a part of the thermosetting resin foam constituting the pad portion 11 has entered the through hole 21, and the porous body 30 is impregnated and cured with the raw material of the thermosetting resin foam. As a result, the porous body 30 is harder than the state in which the raw material of the thermosetting resin foam is impregnated and not cured, and is harder than the pad portion 11. As a result, the porous body 30 accommodated in the large hole portion 23 of the through hole 21 is easily caught in the small hole portion 22, the pad portion 11 is prevented from coming off from the base portion 20, and the pad portion to the base portion 20 is prevented. It is possible to further enhance the stabilization of the fixation of 11.

The seat pad 10 is manufactured as follows. First, the base portion 20 through which the through hole 21 is formed is prepared. The through hole 21 may be formed at the same time as the foam molding of the base portion 20, or may be formed after the foam molding.

Next, the porous body 30 is packed in the large hole portion 23 of the through hole 21 of the base portion 20 (see FIG. 3). As the porous body 30, a material having a cross-sectional area substantially the same as that of the large pore portion 23 may be used, or a material having a cross-sectional area larger than that of the large pore portion 23 may be used.

Next, as shown in FIG. 4, the base portion 20 is set in the upper mold 70A in the foam molding mold 70. At this time, the base portion 20 is set so that the back side surface of the base portion 20 (that is, the surface on which the porous body 30 is exposed) faces the upper mold 70A side.

Then, the raw material 50A of the thermosetting resin foam 50 is injected into the lower mold 70B of the foam molding mold 70, and the foam molding mold 70 is closed (see FIG. 5). At this time, in the present embodiment, the bottom portion 27 of the curved concave surface 26 of the base portion 20 is arranged on the uppermost side of the curved concave surface 26.

Then, the raw material 50A of the thermosetting resin foam 50 is foam-cured in the foam molding mold 70. At this time, as shown in FIG. 6A, when the raw material 50A of the thermosetting resin foam 50 expands by foaming, the foaming gas and the gas such as air in the foaming mold 70 become the base. It is driven to the vicinity of the portion 20 and easily trapped between the thermosetting resin foam 50 and the base portion 20. In particular, since the base portion 20 has a curved concave surface 26, the gas is likely to be trapped in the vicinity of the bottom portion 27 of the curved concave surface 26. Here, since the base portion 20 is provided with the through hole 21 and the through hole 21 is filled with the porous body 30 having air permeability, the gas is passed through the through hole 21 to the outside (that is, the base portion 20). Can be escaped to the back side of). The gas flowing out from the through hole 21 is air (not shown) arranged on the joint between the upper mold 70A and the lower mold 70B and the inner surface of the foam molding mold 70 (for example, a portion facing the porous body 30). It is discharged to the outside of the foam molding mold 70 from a discharge device or the like. In addition, in FIGS. 6 (A) to 6 (C), the illustration of the upper die 70A is omitted.

When the raw material 50A of the thermosetting resin foam 50 further foams and expands, it enters the through hole 21 (see FIG. 6B) and impregnates the porous body 30 (see FIG. 6C). As a result, the expansion and expansion of the raw material 50A of the thermosetting resin foam 50 in the porous body 30 is stopped. When the foam curing of the thermosetting resin foam 50 is completed, the pad portion 11 that covers the base portion 20 from the front side is formed in the foam molding mold 70 (see FIG. 7). Then, the base portion 20 and the pad portion 11 are removed from the foam molding mold 70, and the seat pad 10 is completed.

The configuration and manufacturing method of the seat pad 10 of the present embodiment have been described above. Next, the action and effect of this embodiment will be described.

In the seat pad 10 of the present embodiment, the porous body 30 packed in the through hole 21 penetrating the base portion 20 made of the bead foam molded body in the front and back directions has air permeability. As a result, when the pad portion 11 is foam-molded in the foam molding mold 70 with the base portion 20 set in the upper mold 70A of the foam molding mold 70, the air permeability of the bead foam constituting the base portion 20 becomes high. At worst, the gas accumulated between the base portion 20 and the pad portion 11 can be discharged to the outside through the through hole 21, and it is possible to suppress the occurrence of a missing portion in the seat pad 10. Further, since the porous body 30 is packed in the through hole 21, it is possible to suppress the leakage of the raw material 50A of the thermosetting resin foam 50 from the through hole 21 to the outside during foam molding of the pad portion 11. Become. As described above, according to the present embodiment, it is possible to suppress the occurrence of defects in the seat pad 10, and it is possible to improve the productivity of the seat pad 10.

Moreover, in the present embodiment, the raw material 50A of the thermosetting resin foam 50 constituting the pad portion 11 is impregnated and cured in the porous body 30. Therefore, during the foam molding of the pad portion 11, the expansion and expansion of the raw material 50A of the thermosetting resin foam 50 that has invaded into the through hole 21 while foaming is suppressed in the porous body 30. As a result, the apparent density and hardness of the thermosetting resin that has entered the porous body 30 increases, and it becomes possible to strengthen the prevention of the pad portion 11 from coming off with respect to the base portion 20.

According to the present embodiment, it becomes easy to adjust the size of the bubbles of the foam as the porous body 30 at the time of manufacturing the porous body 30, and the porous body 30 is thermoset while having air permeability. It becomes easy to make the raw material 50A of the sex resin foam 50 difficult to expand and expand. Further, since the porous body 30 is a foam, it becomes easy to fill the through holes with the porous body 30 without gaps by utilizing elasticity.

[Other embodiments]
The present invention is not limited to the above embodiments, and for example, embodiments as described below are also included in the technical scope of the present invention, and various other than the following, as long as they do not deviate from the gist. It can be changed and implemented.

(1) In the above embodiment, the seat pad 10 may be applied to the back pad used for the backrest portion 92 of the seat 90.

(2) In the above embodiment, the porous body 30 is composed of a foam having an open cell structure, but may be composed of a fibrous body such as a non-woven fabric or felt.

(3) In the above embodiment, the through hole 21 is configured to expand stepwise from the front side to the back side of the base portion 20, but may be configured to expand in a tapered shape.

(4) In the above embodiment, the through hole 21 may have a uniform cross-sectional area.

(5) In the above embodiment, the porous body 30 is packed only in a part of the through hole 21 in the penetrating direction of the through hole 21, but may be packed in the entire through hole 21.

(6) In the above embodiment, the size of the porous body 30 may be smaller than that of the large hole portion 23 in the front and back directions of the base portion 20.

(7) In the method for manufacturing the seat pad 10 of the above embodiment, the porous body 30 may not be impregnated with the raw material 50A of the thermosetting resin foam 50 constituting the pad portion 11.

10 Seat pad 11 Pad part 20 Base part 21 Through hole 30 Porous body

Claims (7)

A seat pad in which a base portion made of a bead foam molded body is integrally fixed to the back side of a pad portion made of a soft thermosetting resin foam.
A through hole that penetrates the base portion in the front and back directions,
It has a porous body that is breathable and is packed in the through hole, and has.
The porous body is impregnated with a raw material of the thermosetting resin foam constituting the pad portion and cured. The through hole is provided with a stepped portion that expands the through hole in a stepped manner from the front side to the back side of the base portion.
The seat pad according to claim 1, wherein the porous body is housed in a portion of the through hole on the back side of the stepped portion. The seat pad according to claim 1 or 2, wherein the porous body is made of a foam having an open cell structure. With the base portion made of the bead foam molded product set in the upper mold of the foam molding mold, the raw material of the soft thermosetting resin foam is foam-cured in the foam molding mold to cover the base portion from the front side. It is a method of manufacturing a seat pad that forms a pad portion.
A through hole that penetrates in the front and back directions is formed in the base portion, and
A method for manufacturing a seat pad, which comprises filling the through hole with a porous body having breathability prior to forming the pad portion. The method for manufacturing a sheet pad according to claim 4, wherein when the pad portion is formed, the raw material of the thermosetting resin foam is impregnated into the porous body and cured. A step portion is formed in the through hole so as to expand the through hole stepwise from the front side to the back side of the base portion.
The method for manufacturing a seat pad according to claim 5, wherein the porous body is housed in a portion of the through hole on the back side of the step portion. The method for producing a seat pad according to any one of claims 4 to 6, wherein a foam having an open cell structure is used as the porous body.

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