JP7209564B2 - Vehicle cushion pad and manufacturing method thereof - Google Patents

Description

TECHNICAL FIELD The present invention relates to a vehicle cushion pad that constitutes a vehicle seat and a manufacturing method thereof.

The cushion pad that forms the seat of a vehicle seat for a vehicle, such as an automobile, has been made of a soft polyurethane foam molding. . Such a cushion pad is made by using a foaming mold that is turned upside down from the one installed in a vehicle, and after setting a preformed bead foam (the "first foam" of the present invention) in the upper mold, A soft polyurethane foam molded article (the “second foamed article” of the present invention) is foam-molded.
Here, if the setting of the first foam to the upper mold is neglected, the foam raw material will enter the gap between the upper mold and the first foam during the foam molding process of the second foam. After molding, the infiltrated foaming raw material forms a cured film k as shown in FIG. 12 and adheres to the rear surface 2b of the first foam, and is difficult to remove after demolding. In addition, grooves 22 for fastening tools are provided on the back surface 2b of the first foam. If the foam material enters the grooves 22, the fasteners of the surface covering the cushion pad cannot be stopped. Removing the hardened material k of the foaming raw material is a difficult task.
For this reason, several inventions have been proposed to prevent the foaming raw material from entering the gap during the foam molding process of the second foam (for example, Patent Document 1).

JP 2018-175504 A

Patent Document 1 discloses, as described in claim 2, "... a seat core material (in the present invention, a "first foam ")", and as described in claim 7, "the upper die is provided with a ridge portion, and when the seat core material is set on the upper die, the ridge portion is attached to the seat core material. It abuts on the formed abutment planned region.
However, in the first foam of the bead foam, unpredictable molding shrinkage and twisting occur in the foam molding, and individual dimensions vary. However, it becomes difficult to set the first foam to the upper mold.
In addition, in FIG. 1 of Patent Document 1, a planned contact region 24, a convex portion 26, a recessed portion 30, and a urethane impenetrable region 32 are arranged in order from the outer peripheral edge of the back surface of the first foam toward the center of the back surface. there is Although not shown in FIG. 1, the grooves for the fasteners in the outer skin described above are provided in the urethane impenetrable region 32 . The groove for the locking tool should be provided near the outer peripheral edge of the back surface of the first foam so as not to increase the size of the skin unnecessarily and not to take time to cover the cushion pad with the skin. Inevitably, the distance between the expected contact area 24, the projection 26, and the recess 30 is reduced, and the projection and the projection are likely to interfere with each other. The number of parts of the first foam that can be set and adapted to the upper die is reduced, resulting in a decrease in yield.

The present invention solves the above problems by expanding the allowable range in which the first foam can be set in the upper mold in the foam molding of the second foam, where the dimensions of the first foam vary due to molding shrinkage, etc. It is an object of the present invention to provide a cushion pad for a vehicle and a method of manufacturing the same, which prevent a foam material from entering a gap between a foam and an upper mold.

In order to achieve the above object, the gist of the invention according to claim 1 is to provide a seat portion layer having a contact surface portion on the side that a seated occupant contacts on a first foam body that exposes the back surface and becomes a lower layer. In the vehicle cushion pad in which the laminated second foam is foam-molded, the first foam is foam-molded with a smaller unit weight than the second foam, and a bank-like standing wall is formed on the back surface thereof. and the upright wall portion is provided so as to stand up along the peripheral edge of the back surface of the first foam, and the upright wall portion has a restoring force against compressive deformation. on the cushion pad for In the vehicle cushion pad according to claim 2, in claim 1, the standing wall portion is formed into a pair of plate-shaped portions branched into two by forming a groove extending from the tip end to the base end in a side view. It is characterized by The vehicle cushion pad according to the invention of claim 3 is characterized in that, in claim 2, the groove bottom of the groove extends beyond the back surface of the first foam around the base end of the standing wall portion, and the main portion of the first foam It is characterized by entering into. The cushion pad for a vehicle according to claim 4 is the vehicle cushion pad according to claims 1 to 3, wherein the vertical wall portion has a length exceeding the groove length of the locking groove of the outer skin provided on the back surface of the first foam. It is characterized in that it is provided on the side and is arranged closer to the periphery of the rear surface of the first foam than the locking groove.
The gist of the invention according to claim 5 is a second foam body in which a seat layer having a contact surface portion on the side where a seated occupant contacts is laminated on a first foam body that exposes the back surface and becomes a lower layer. In the method of manufacturing a vehicle cushion pad by foam molding, the first foam is foam-molded with a smaller unit weight than the second foam, and is restored against compression deformation along the peripheral edge of the back surface. While forming a bank-shaped standing wall portion having a force, a recessed hole is formed in a portion of the upper mold cavity surface corresponding to the standing wall portion, and the back side of the first foam is directed upward into the recessed hole. After inserting the vertical wall portion and setting the first foam in the upper mold, the foaming raw material for the second foam is injected onto the cavity surface of the lower mold and the mold is closed, and then the second foam is foam-molded. A method for manufacturing a vehicle cushion pad characterized by: A method of manufacturing a cushion pad for a vehicle according to claim 6 of the invention is characterized in that, in claim 5, the standing wall portion is in the form of a pair of plate pieces branched into two by forming a groove extending from the tip end to the base end thereof in a side view. It is characterized by being a part. The method for manufacturing a vehicle cushion pad according to the seventh aspect of the invention is characterized in that, in the sixth aspect, the groove bottom of the groove is extended beyond the rear surface of the first foam around the base end of the standing wall portion, It is characterized in that it is made to enter even the main part. In the method for manufacturing a vehicle cushion pad according to claim 8 of the invention, in claims 5 to 7, the hole width between the hole bottom side inner walls running in the longitudinal direction of the recessed hole is larger than the hole width between the hole bottom side inner walls. Further, the hole width between the hole mouth side inner walls is made larger than the wall width of the base end side portion related to the corresponding standing wall portion, so that when the standing wall portion is inserted into the concave hole, the standing wall portion can be formed. It is characterized in that the base end portion is loosely fitted. The method for manufacturing a vehicle cushion pad according to the ninth aspect of the invention is characterized in that, in the eighth aspect, the recessed hole is provided with a stepped surface on the way from the hole bottom toward the hole mouth side, and the recessed hole The hole width is widened stepwise from the hole bottom side inner wall running in the longitudinal direction of the hole to the hole mouth side inner wall. In the method for manufacturing a vehicle cushion pad according to claim 10, in claims 5 to 9, the vertical wall provided on the back surface of the first foam has a length exceeding the groove length of the locking groove of the outer skin. It is characterized in that the upright wall portion is provided on the side of the groove and is arranged closer to the periphery of the rear surface of the first foam than the locking groove.

In the vehicle cushion pad and the method for manufacturing the same of the present invention, even if the first foam has variations in dimensions due to molding shrinkage, etc., the tolerance for variation is widened, and the second foam is foam-molded using this as an insert. It can be carried out well and exhibits excellent effects such as yield improvement and productivity improvement.

1 is a perspective view of a cushion pad viewed from the back side in one embodiment of a vehicle cushion pad and a method of manufacturing the same according to the present invention; FIG. FIG. 2 is a sectional view taken along the line II-II of FIG. 1; 3 is an enlarged cross-sectional view of another aspect in place of FIG. 2; FIG. 3 is an enlarged cross-sectional view of another aspect in place of FIG. 2; FIG. It is the perspective view which looked at the cushion pad of FIG. 1 from the surface side. FIG. 4 is an explanatory cross-sectional view in which the first foam having standing walls of FIGS. 2 and 3 is set in the upper mold; FIG. 7 is an enlarged view of the surroundings of the standing wall portion arranged on the left side of FIG. 6 in the first foam that has been set in the upper mold; FIG. 7 is an enlarged view of the surroundings of the standing wall portion arranged on the right side of FIG. 6 in the first foam that has been set in the upper mold; FIG. 10 is a cross-sectional view of injecting a foaming raw material after setting the first foam on the upper mold; It is explanatory sectional drawing of mold closing. It is explanatory sectional drawing which foam-molded the 2nd foam molding. 1 is an explanatory perspective view of a conventional technique; FIG.

Hereinafter, a vehicle cushion pad (hereinafter also simply referred to as "cushion pad") according to the present invention and a method for manufacturing the same will be described in detail.
1 to 11 show an embodiment of the cushion pad and its manufacturing method according to the present invention, wherein FIG. 1 is a perspective view of the back side of the cushion pad, FIG. 2 is a cross-sectional view taken along line II-II of FIG. 2, FIG. 5 is a front side perspective view of the cushion pad, FIG. 6 is a cross-sectional view in which the first foam having the standing wall portion of FIGS. 2 and 3 is set in the upper mold, and FIG. 7 is the top In the first foam set in the mold, an enlarged view of the standing wall portion on the left side of FIG. 6, FIG. 8 is an enlarged view of the standing wall portion on the right side of FIG. 6, and FIG. FIG. 10 is a cross-sectional view of closing the mold, and FIG. 11 is a cross-sectional view of the second foam molding. In each drawing, the essential parts of the invention are emphasized for easier understanding of the drawings, and parts that are not directly related to the present invention are simplified or omitted.

(1) Vehicle Cushion Pad The vehicle cushion pad 1 is a cushion pad that supports the lower half of the body of a seated passenger. It is applied to the cushion pad of the vehicle rear seat (Figure 1, Figure 5). When the cushion pad 1 is covered with a skin to form a seat cushion, a rear seat having an auxiliary seat part 3C in the width direction of the vehicle can be obtained by combining the known seat back with the skin on the back pad. FIG. 5 shows the cushion pad 1 installed in a vehicle. The horizontal direction of the paper indicates the vehicle width direction, and the upper side of the paper indicates the upper side of the vehicle.
A cushion pad 1 comprises a first foam 2 and a second foam 3 .

The first foam 2 is a raised foam molding that occupies the lower layer of the cushion pad 1 (FIGS. 1 and 2). It has a smaller unit weight and a smaller apparent density than the second foam 3, but has a large hardness. Within a predetermined range, it is foam-molded with a restoring force against compressive deformation caused by receiving an external force. It is a block-shaped bead foam molded by in-mold foam molding after preliminary foam molding of raw material beads. The bead foam is preferably foamed polystyrene, foamed polypropylene, foamed polyethylene, or a molded body containing at least one of these. Most of the volume of the foamed beads having air bubbles sealed therein is a gas, and the foamed body is lightweight, harder than the second foamed body 3, and has hardness and shape retention as a raising member for the cushion pad 1. - 特許庁

The first foam body 2 has a bank-like standing wall portion 24 protrudingly formed on the back surface 2b thereof. The standing wall portion 24 is formed by rising from the main portion 23 of the first foam 2 so as to stand along the rear peripheral edge 21 of the first foam 2 . In the foam molding of the second foam 3, which will be described later (Fig. 10), the foaming raw material g is likely to enter from the gap between the upper mold 9 and the first foam 2 set therein, for example, at the back surface 2b of the first foam. In the case where hardened material k of foaming raw material g is likely to be formed by entering from the lower left portion of FIG. The upright wall portion 24 is rectangular with a uniform cross-sectional shape in the longitudinal direction as shown in the drawing, and is protuberantly formed on the rear surface 2b of the first foam 2. As shown in FIG. The standing wall portion 24 has a restoring force against compressive deformation of the foamed beads. In particular, by forming the standing wall portion 24 in a wall-like or plate-like shape, the function of restoring force against compressive deformation is enhanced.
In FIG. 12, the hardened material k of the foaming raw material g reaches even the locking groove 22 of the skin. Therefore, in FIG. 1, the standing wall portion 24, which is slightly elevated like a bank, is arranged on the side of the rear surface peripheral edge 21 of the first foam 2 rather than the locking groove 22, and on the rear surface 2b of the first foam 2. It is provided on the side of the groove with a length exceeding the groove length of the locking groove 22 of the outer skin to be provided. It is an upright wall portion 24 along the locking groove 22, and both ends thereof extend to a point beyond the groove ends of the locking groove 22 to prevent the intrusion of the foaming raw material g.

The vertical wall portion 24 in FIG. 1 has a rectangular or trapezoidal cross-sectional shape shown in FIG.
The standing wall portion 24 in FIG. 3 has a V-shaped groove 25 notched in the rectangular cross-sectional shape of FIG. 2 when viewed from the side. The standing wall portion 24 forms a V-shaped groove 25 extending from the top surface of the tip 242 to the base end 243, and although it is connected to the first foam main portion 23 at the base end portion 244, the tip end side 242 is divided into two. A pair of branched plate-like portions 24A and 24B are formed. The V-shaped groove 25 runs in the direction perpendicular to the paper surface of FIG. 3, and cuts out in a V-shape the entire portion where the standing wall portion 24 exists. A pair of plate piece-like portions 24A and 24B stand and extend from the first foam main portion 23 via the base end portion 244 . The standing wall portion 24 of FIG. 3 has a V-shaped groove 25, so that when an external force is applied, the plate piece-like portion 24 having a wall width about half that of the standing wall portion 24 of FIG. It becomes easy to bend.

Furthermore, in the V-shaped groove 25 of FIG. Enter up to 231. Since the groove bottom 251 is V-shaped cut to the main region 231 of the first foam 2, the upright wall surface 241 of the plate piece 24 is more easily bent when an external force is applied. The groove bottom 251 runs in the direction perpendicular to the paper surface of FIG. It even enters the first foam main portion 23 . Each of the plate-shaped portions 24A and 24B becomes more easily elastically deformed in response to the external force received. In addition, the base end portion 244 of the standing wall portion 24 is thicker than the base end portion 244, which has the effect of preventing the plate piece portions 24A and 24B from bending, breaking, and breaking.

As shown in FIG. 4, the vertical wall surface 241 of the vertical wall portion 24 is inclined upward at an angle α. The standing wall portion 24 has a trapezoidal cross-sectional shape with a tip 242 as the upper base in a side view, and the U-shaped groove 25 is cut out. Since both wall surfaces 241 of the vertical wall portion 24 are inclined to approach each other on the protruding end side, even if the groove 25 is U-shaped instead of V-shaped, the thickness of the base end portion 244 of the vertical wall portion 24 is consequently greater. Increase. This has the effect of preventing the plate piece portions 24A and 24B from bending, breaking, and breaking. A U-shaped groove 25 is formed to divide the vertical wall portion 24 into a pair of branched plate-shaped portions 24A and 24B. The groove 25 provided in the standing wall portion 24 may be V-shaped, U-shaped, or U-shaped, and is not limited thereto. Other configurations of the grooves are the same as those in FIG. 4, and description thereof is omitted.
Reference numerals 2A, 2B, and 2C indicate the main lower layer, the side lower layer, and the auxiliary seat lower layer. Reference numeral 28 denotes the rear surface 2b of the first foam, which is a protruding portion formed by raising a part of the rear base portion 27, and reference numeral 281 denotes a protruding wall.

The second foam body 3 has a seat layer 31 with a contact surface portion 311 on the side that the seated occupant contacts, and is a cushion body formed of a soft polyurethane foam molding. A second foam 3 is foam-molded by laminating a seat layer 31 on the first foam 2 that exposes the back surface 2b and serves as a lower layer for raising. A seated occupant comes into contact with the contact surface portion 311 via a skin (not shown) that covers the cushion pad 1 .

In FIG. 5 , the second foam 3 has a seat layer 31 covering the core pad top surface 2 a and a side peripheral layer 32 covering the side surfaces 2 d of the first foam 2 . The upper surface of the seat portion layer 31 related to the second foam 3 becomes the design surface 3a on the side of the contact surface portion 311 with which the seated occupant contacts, and the outer surface of the side peripheral layer 32 becomes the side surface side design surface 3d of the second foam 3. . The second foam 3 covers and integrates the first foam 2 except for the back surface 2b of the first foam 2, which also serves as the back surface 1b of the cushion pad, to complete the cushion pad 1. - 特許庁
Although illustration is omitted, the first foam 2 is provided with a gas venting hole disclosed in Japanese Patent Laid-Open No. 2017-206077, which penetrates from the top surface 2a to the back surface 2b. It has a recess. In the foam molding of the second foam 3, which will be described later, the second foam 3 fills the through-holes and depressions, so that the second foam 3 and the first foam 2 are integrally reinforced. Reference numeral 3A denotes a main portion of the passenger seat, reference numeral 3B denotes a side portion, reference numeral 3D denotes a slope, reference numeral 3E denotes a joint portion with a backrest, and reference numeral 39 denotes a suspension groove.

(2) Manufacturing Method of Vehicle Cushion Pad The cushion pad 1 employs, for example, the first foam 2 as shown in FIG. 6 and is manufactured as follows (FIGS. 6 to 11). Using the foam molding die 7, the second foam 3 in which the contact surface portion 311 on the side that the occupant contacts is formed of a soft polyurethane foam molding is foam molded. A vehicle cushion pad 1 to be integrated is manufactured.

Prior to manufacturing the cushion pad 1, the first foam 2 and the foam mold 7 are prepared. The first foam 2 is the same as that described in (1) the cushion pad, so a detailed description is omitted. Here, the vertical wall portion 24 having a rectangular cross section is provided on one side of the back surface 2b, and the vertical wall portion 24 consisting of a pair of plate piece-shaped portions 24A and 24B is provided on the other side. Use Both wall portions 24 are provided on the side of the groove with a length exceeding the groove length of the locking groove 22 of the outer skin, and are arranged closer to the rear peripheral edge 21 side than the locking groove 22 .
The foaming mold 7 is a split mold as shown in FIG. 9, and a lower mold 8 and an upper mold 9 are connected so as to be openable and closable. When the mold is closed, there are a lower mold cavity surface 81 which is concaved in a bowl shape as a whole and forms a design surface of the contact surface portion 311, and an upper mold cavity surface 91 which is generally flat and aligned with the back surface 2b of the first foam 2. Then, a cavity C for the cushion pad 1 is formed (Fig. 10). When the first foam 2 is set on the upper mold 9 , a concave hole 92 is formed in a portion of the upper mold cavity surface 91 corresponding to the standing wall portion 24 . The recessed hole 92 has a uniform cross-sectional shape in the longitudinal direction so as to match the shape of the standing wall portion 24 in the longitudinal direction, and the recessed hole 92 is made slightly larger than the standing wall portion 24 .

Furthermore, the hole width between the hole-side inner walls 924 is set larger than the hole width between the hole-bottom-side inner walls 922 running in the longitudinal direction of the recessed hole 92, and the hole width between the hole-side inner walls 924 is set to the corresponding upright wall. It is made larger than the wall width of the base end side portion 244 related to the portion 24 (FIG. 8). Then, by inserting the standing wall portion 24 into the concave hole 92, the base end portion 244 of the standing wall portion 24 is loosely fitted. The recessed hole 92 may be gradually enlarged in a trumpet shape toward the hole mouth 920, but the main recessed hole 92 is provided with a stepped surface 923 on the way from the hole bottom 921 to the hole mouth 920 side, and the stepped surface 923 is formed. The width of the hole widens stepwise from the hole bottom side inner wall 922 to the hole mouth side inner wall 924 through the hole.
The foam molding die 7 molds the cushion pad 1 shown in FIG. 5 upside down.

The cushion pad is manufactured by first using the foaming mold 7 and the first foam 2, with the rear surface 2b side of the first foam 2 facing up, and fitting the two vertical wall portions 24 into the respective recessed holes 92. Then, the first foam 2 is set on the upper mold 9.
A concave hole 92 is provided at a position corresponding to the standing wall portion 24 on the upper mold cavity surface 91 . If the dimensional error (positional deviation of the standing wall portion 24) due to molding shrinkage of the first foam 2 is small, the standing wall portion 24 having a rectangular cross section as shown in FIG. A U-shaped groove is sufficient. Further, even if the standing wall portion 24 is reduced in size due to molding shrinkage and a gap is formed between it and the recessed hole 92 of the U-shaped groove, no particular problem occurs. When the second foam 3 is foam-molded, the foaming raw material g has a large resistance and takes a long time to pass through the narrow gap where the cross section is curved in a U-shape. The foaming raw material g hardens in the course of passage and can be stopped.

In this embodiment, the width of the hole between the opening-side inner walls 924 is made larger than the wall width of the proximal end portion 244 related to the standing wall portion 24, as described above.
7, which is a cross-sectional view of the recessed hole 92, a hole bottom 921 and both hole bottom side inner walls 922 form a conformal shape, and from the lower ends of both hole bottom side inner walls 922, both spread horizontally outward to form a step. A surface 923 is formed. Further, the hole-side inner walls 924 extend vertically from the outer ends of the stepped surfaces 923 to increase the hole width between the hole-side inner walls 924 . The hole space between both hole mouth side inner walls 924 is made larger than the wall width of the base end side part 244 related to the corresponding standing wall part 24, and the standing wall part 24 is inserted and set into the concave hole 92 having the hole space. .

Specifically, it is as follows. Insertion and setting of the standing wall portion 24 into the recessed hole 92 on the left side of FIG. The vertical wall portion 24 is inserted without difficulty to form the set shown in FIG. 7(a).
On the other hand, even if the first foam 2 shown in FIG. can.

In FIG. 7(b), when the standing wall portion 24 is inserted into the concave hole 92, the right plate piece portion 24B creates a gap ε between the right hole bottom side inner wall 922 and the right hole bottom side inner wall 922 due to the deviation SD. , fits in the recessed hole 92 .
In addition, the left plate-like portion 24A bends from the upright state and tilts rightward at an angle θ, and in this case also, the tip 242 side fits well into the hole space on the hole bottom 921 side of the concave hole 92 . Due to the presence of the groove 25, the left plate piece 24A is more easily bent and tilts. The groove space of the groove 25 is reduced according to the size of the deviation SD due to the dimensional error, thereby facilitating the compressive deformation of the plate piece-like portion 24 . Even when the deviation SD of the left plate-shaped portion 24A is large, if the operator applies a little force, the left plate-shaped portion 24A tilts more and the tip 242 side enters between the inner walls 922 on the hole bottom side.
However, on the base end 243 side of the left plate piece-shaped portion 24A, the root is connected to the first foam main portion 23, and if it is a normal recessed hole 92 formed only by the hole width between the hole bottom side inner walls 922, , it does not enter the concave hole 92 . However, in the recessed hole 92, the hole width between the hole mouth side inner walls 924 is larger than the hole width between the hole bottom side inner walls 922 running in the longitudinal direction. Since the hole bottom side inner wall 922 is formed to allow the base end side portion 244 of the plate piece 24 to be loosely fitted, the entire vertical wall portion 24 fits in the recessed hole 92 in good proportion.

Even if the vertical wall portion 24 of the first foam 2, which has dimensional variations due to molding shrinkage, is bent and inserted into the concave hole 92 by shifting the position, the vertical wall portion 24 is concave on the base end 243 side compared to the tip 242 side. Fitting into the hole 92 is difficult. Even if the standing wall portion 24 is bent, the root of the base end 243 side directly connected to the main portion 23 of the first foam 2 hardly displaces, making it difficult. Therefore, by increasing the width of the hole between the opening-side inner walls 924 and loosely fitting the proximal end portion 244, the first foam 2, which conventionally has dimensions outside the allowable range due to molding shrinkage, etc. It is rescued and set to the upper mold 9 is made possible.

Further, the concave hole 92 of the present embodiment is provided with a stepped surface 923 on the way from the hole bottom 921 to the hole mouth 920 side, and through the stepped surface 923, the hole bottom side inner wall running in the longitudinal direction of the concave hole 92 is provided. The width of the hole is widened stepwise from 922 to the inner wall 924 on the side of the hole. The left plate-like portion 24A in FIG. 7B is compressed and deformed by being inserted into the recessed hole 92 and is tilted. The standing wall surface 241 presses and seals the corner CT between the hole bottom side inner wall 922 and the hole bottom side inner wall 922 due to the reaction force due to the compressive deformation. This seal effectively prevents the penetration of the foam material g during the foam molding process of the second foam 3 (details will be described later).

Even if the pair of plate-like portions 24A and 24B shown in FIG. 7B, which are shifted leftward due to dimensional errors with respect to the concave hole 92, are replaced with the vertical wall portion 24 having a rectangular cross section shown in FIG. The standing wall portion 24 can be set in the concave hole 92 as shown in (a) and (b). Since there is no groove space for the groove 25, the bending and tilting of the vertical wall portion 24 are restricted, so the allowable range of the vertical wall portion 24 that can be inserted and set in the recessed hole 92 is narrowed. The first foam 2 that is outside is also applicable, and the number of things that can be adopted increases.
Although the case where the vertical wall portion 24 is displaced to the left due to molding shrinkage or the like has been described, the arrangement is only reversed when it is displaced to the right, and a description thereof will be omitted.
Thus, the vertical wall portion 24 is securely inserted into the concave hole 92 and the first foam 2 is set in the upper mold 9 .

Thereafter, the foaming raw material g for the second foam 3 is injected onto the lower mold cavity surface 81 using the injection nozzle NL or the like (FIG. 9).
Subsequently, the upper mold 9 is operated to close the mold (FIG. 10). Closing the upper mold 9 and the lower mold 8 creates a cavity C for the cushion pad 1 in which the first foam 2 is inserted. In this embodiment, the mold is closed after the foaming material g is injected, but the foaming material g can be injected after the mold is closed.

After the mold is closed, the second foam 3 is foam-molded. A second foam 3 having a contact surface portion 311 on the design surface side and having an inner surface 3b on the opposite side thereof in contact with the top surface 2a of the first foam 2 to form a seat layer 31 is foam-molded. The mold closed state of FIG. 10 is maintained for a predetermined time, and the second foam 3 of the soft polyurethane foam is foam-molded. Forming the contact surface portion 311 with the lower mold cavity surface 81, and foam molding the second foam 3 in which the inner surface 3b on the side opposite to the contact surface portion 311 is brought into contact with the top surface 2a of the first foam 2. (Fig. 11).
When the foam molding of the second foam 3 is completed and removed from the mold, the desired cushion pad 1 that has achieved weight reduction by incorporating the first foam 2 can be obtained.
Reference numeral 88 denotes a hanging groove protrusion, and reference numerals 89 and 99 denote mold-matching surfaces on the lower die 8 side and the upper die 9 side.

(3) Effect According to the vehicle cushion pad and the manufacturing method thereof configured as described above, even if the vertical wall portion 24 is misaligned SD due to molding shrinkage or the like of the first foam 2, the second foam 3 is The first foam 2 can be set in the upper mold 9 by foam molding. As in Claims 1 and 5, the bank-like vertical wall portion 24 is formed on the rear surface 2b of the first foam body, and the vertical wall portion 24 has a restoring force against compression deformation. 2 can face each other flexibly even if there is some dimensional variation, a recessed hole 92 is formed in the portion of the upper mold cavity surface 91 corresponding to the standing wall portion 24, and the standing wall portion 24 is inserted into the recessed hole 92. Then, the first foam can be set on the upper mold 9 by pressing.
Then, a gap is generated between the upper mold cavity surface 91 outside the recessed hole 92 and the first foam back surface 2b. Even if the foaming raw material g tries to enter the center of the hole, the entry can be prevented by the recessed hole 92 and the standing wall portion 24 set therein. The inner wall of the recessed hole 92 bent in a U-shaped cross section and the standing wall surface 241 of the standing wall portion 24 are in contact with or close to each other. It hardens while the foaming material g enters the winding narrow passages. To effectively suppress foam raw material g entering a gap between an upper mold 9 and a second foam 3 during foam molding of the second foam 3. - 特許庁In the foam molding of the second foam 3, the foam raw material g does not enter the rear surface 2b of the first foam over the vertical wall portion 24. - 特許庁

As in claims 2 and 6, even if the vertical wall portion 24 is displaced and does not fit in the concave hole 92 of the upper mold 9 as it is, the vertical wall portion 24 is a groove extending from the tip 242 to the base end 243 in a side view. 25 is formed to form a pair of plate-like portions 24A and 24B, the groove space of the groove 25 is reduced and the vertical wall portion 24 is bent, so that the vertical wall portion 24 can be accommodated in the concave hole 92.例文帳に追加
As in claims 3 and 7, the groove bottom 251 of the groove 25 extends beyond the rear surface 2b of the first foam 2 around the base end 243 of the standing wall portion 24, and extends into the main region of the first foam 2. If the vertical wall portion 24 is intruded into the 231, the vertical wall portion 24 is more likely to tilt. Even if the dimensional error of the first foam body 2 increases and the vertical wall portion 24 is misaligned SD, the number of foam bodies that can be set on the upper die 9 increases, leading to an improvement in yield.

As in claim 8, the hole width between the hole opening side inner walls 924 is made larger than the hole width between the hole bottom side inner walls 922 running in the longitudinal direction of the concave hole 92, so that the standing wall portion 24 can be inserted into the concave hole 92. When the base end portion 244 of the standing wall portion 24 is loosely fitted, the standing wall portion 24 can be smoothly inserted into the recessed hole 92 even if the displacement width of the standing wall portion 24 is further increased. Unlike the tip 242 side, the base end 243 side of the base of the standing wall portion 24 cannot be moved to evade even if it is bent. It is difficult to fit in the concave hole 92 of . However, since the hole opening 920 side is sized so that the proximal end portion 244 of the standing wall portion 24 can be loosely fitted, the standing wall portion 24 can be easily fitted into the recessed hole 92 even if the deviation SD of the standing wall portion 24 becomes large. can be accommodated. The standing wall portion 24 that is compressed and deformed and inserted hits a portion toward the hole bottom 921 , and the elastic restoring force associated with the compressive deformation can prevent the foaming raw material g from entering during the molding of the second foam 3 .

As in claim 9, when the recessed hole 92 has a stepped surface 923, the width of the recessed hole 92 is expanded stepwise from the hole bottom side inner wall 922 to the hole mouth side inner wall 924. By inserting the vertical wall portion 24, the intrusion of the foaming raw material g by the vertical wall portion 24 can be effectively stopped. As shown in FIG. 7(b), the standing wall portion 24 bends and tilts, resulting in compressive deformation. and seal. In the foam molding of the second foam 3, even if the foaming raw material g enters from the back surface peripheral edge 21 of the first foam 2 set in the upper mold 9 toward the center of the back surface 2b, the seal prevents the corner CT. You can definitely stop it in places. After demolding, the conventional work of removing the cured product k is eliminated, leading to improvement in workability and quality.

As in Claims 4 and 10, the vertical wall portion 24 is provided on the side of the groove with a length exceeding the groove length of the locking groove 22 of the outer skin, and the back surface peripheral edge 21 is formed from the locking groove 22. If it is arranged on the side, the locking groove 22 is guarded by the standing wall portion 24 in front of it. It is possible to effectively prevent the foaming raw material g from entering the locking groove 22 during the molding of the second foam 3 . Only the vertical wall portion 24 is provided on the first foam 2, and the number of constituent elements is small, and the complicated structure as in Patent Document 1 does not cause interference between the ridges and the convex portions. This contributes to improving the productivity of the cushion pad 1.
As described above, the present vehicle cushion pad and its manufacturing method have a large tolerance range for the dimensions of the first foam body 2 that can be set in the upper mold 9, and the yield of the first foam body 2, which is likely to cause molding shrinkage, etc. In addition, in the foam molding of the second foam 3, it is extremely beneficial to reliably prevent the foaming raw material g from entering the back surface 2b of the first foam.

It should be noted that the present invention is not limited to those shown in the above embodiments, and various modifications can be made within the scope of the present invention according to the purpose and application. The shape, size, number, material, etc. of the cushion pad 1, the first foam 2, the standing wall portion 24, the second foam 3, the foam mold 7, the recessed holes 92, etc. can be appropriately selected according to the application.

REFERENCE SIGNS LIST 1 cushion pad 2 first foam 2b rear surface 21 rear peripheral edge 22 outer skin locking groove 24 standing wall portion 25 V-shaped groove (U-shaped groove)
3 second foam 31 seat layer 311 contact surface portion 81 lower mold cavity surface 91 upper mold cavity surface 92 concave hole 922 hole bottom side inner wall 923 step surface 924 hole mouth side inner wall g foaming material

Claims (10)

A cushion pad for a vehicle in which a second foam is foam-molded in which a seat portion layer having a contact surface portion on a side that a seated occupant contacts is laminated on a first foam that is a lower layer with its back surface exposed,
The first foam is foam-molded with a unit weight smaller than that of the second foam, and a bank-shaped standing wall portion is formed on the back surface of the first foam, and along the periphery of the back surface of the first foam, The standing wall portion is provided so as to stand upright, and the standing wall portion has a restoring force against compressive deformation . A cushion pad for a vehicle, characterized by being a plate-like portion . 2. The vehicle cushion pad according to claim 1 , wherein the groove bottom of the groove extends beyond the rear surface of the first foam around the base end of the standing wall portion and extends into the main portion of the first foam. The vertical wall portion is provided on the side of the groove with a length exceeding the groove length of the locking groove of the outer skin provided on the back surface of the first foam, and 3. The vehicle cushion pad according to claim 1 or 2 , which is arranged on the peripheral side of the rear surface of the vehicle. A method for manufacturing a vehicle cushion pad by foam-molding a second foam in which a seat portion layer having a contact surface portion on a side that a seated occupant contacts is laminated on a first foam that is a lower layer with its back surface exposed. in
The first foam is foam-molded with a unit weight smaller than that of the second foam, and along the peripheral edge of the back surface of the first foam, a bank-like standing wall portion having a restoring force against compressive deformation is formed. , forming a concave hole in a portion of the upper mold cavity surface corresponding to the standing wall portion,
After turning the back side of the first foam upward and inserting the vertical wall portion into the concave hole to set the first foam in the upper mold,
Injecting the foaming raw material for the second foam onto the lower mold cavity surface and closing the mold,
A method for manufacturing a cushion pad for a vehicle, characterized in that the second foam is then foam-molded. 5. The method of manufacturing a cushion pad for a vehicle according to claim 4 , wherein said standing wall portion is a pair of plate-like portions branched into two by forming a groove extending from a tip end to a base end thereof in a side view. 6. The manufacturing of the vehicle cushion pad according to claim 5 , wherein the groove bottom of the groove extends beyond the rear surface of the first foam around the base end of the standing wall portion and enters into the main portion of the first foam. Method. The hole width between the hole-side inner walls running in the longitudinal direction of the recessed hole is larger than the hole width between the hole-bottom-side inner walls running in the longitudinal direction, and the hole width between the hole-side inner walls is related to the corresponding standing wall portion. 7. According to any one of claims 4 to 6 , wherein the wall width of the base end side portion is made larger than the wall width of the base end side portion so that the base end portion of the upright wall portion is loosely fitted when the standing wall portion is inserted into the recessed hole. A method for manufacturing the vehicle cushion pad described. The concave hole is provided with a step surface on the way from the hole bottom to the hole mouth side, and the hole width is stepped from the hole bottom side inner wall running in the longitudinal direction of the concave hole to the hole mouth side inner wall via the step surface. 8. The method for manufacturing a vehicle cushion pad according to claim 7 , wherein the cushion pad is spread out into a shape. The standing wall portion provided on the back surface of the first foam has a length exceeding the groove length of the locking groove of the outer skin and is provided on the side of the groove, and the first foam is positioned further than the locking groove. 9. The method for manufacturing a vehicle cushion pad according to any one of claims 4 to 8 , wherein the standing wall portion is arranged on the peripheral edge side of the rear surface of the vehicle. A foam that forms a vehicle cushion pad by foam-molding a cushion body on the surface side,
The back surface is exposed, and a bank-shaped standing wall portion is formed on the back surface, and the standing wall portion is provided so as to stand up along the peripheral edge of the back surface, and the standing wall portion has a restoring force against compressive deformation. A foamed body characterized by comprising a pair of plate-like portions branched into two by forming a groove extending from the protruding end to the base end thereof when viewed from the side.

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