JP7341635B2 - Beaded foam molded parts for vehicle seats - Google Patents

Description

The present invention relates to a beaded foam molded member for vehicle seats.

BACKGROUND ART Pad bodies with a two-layer structure have been known as cushioning materials for vehicle seats. Patent Document 1 below discloses a pad body in which a cushion member, which is a foam made by foaming AS resin (acrylonitrile, styrene copolymer), is insert-molded on the side opposite to the seating surface of urethane foam made by foam-molding polyurethane resin. has been done. Normally, when manufacturing this pad body, a lower mold and an upper mold are used, and when the upper mold is closed to the lower mold, a cavity corresponding to the shape of the pad body is formed between the lower mold and the upper mold. Use the template. The cavity surface of the lower mold is formed in a shape corresponding to the shape of the seating surface side of the pad body, and the cavity surface of the upper mold is formed in a shape corresponding to the shape of the side opposite to the seating surface of the pad body. Then, the surface of the cushion member opposite to the seating surface of the upper mold is mechanically fitted to the cavity surface of the upper mold, or the magnetic force acting between the magnet embedded in the cavity surface of the upper mold and the iron member inserted into the cushion member is used. While the pad body is held, a foamed polyurethane resin raw material is injected into the cavity surface of the lower mold, and the upper mold is closed to the lower mold to perform foam molding, thereby producing a pad body.

Japanese Patent Application Publication No. 2010-125138

In the pad body described in Patent Document 1, the surface of the cushion member opposite to the seating surface must be attached to the cavity surface of the upper mold without any gap during the foam molding process of the foamed polyurethane resin raw material. be. During the process of foaming and hardening of the foamed polyurethane resin raw material, if there is a gap between the cavity surface of the upper mold and the surface opposite to the seating surface of the cushion member, a part of the foamed polyurethane resin raw material will enter the gap and foam and harden. do. Then, a portion of the foamed polyurethane resin raw material hardens in an unfoamed state within the gap, resulting in a shortage of the foamed polyurethane resin raw material forming the pad body, which may result in underfilling inside the pad body. Furthermore, if the amount of foamed polyurethane resin raw material to be added is increased in order to prevent this underfilling, the material cost and weight of the pad body will increase. In order to prevent this, it is necessary for the cushion member to be molded into a predetermined shape, but there is a problem that deformation such as warping or twisting tends to occur due to the effects of molding shrinkage and the like.

The present invention was devised in view of these points. An object of the present invention is to provide a bead foam molded member that suppresses deformation during molding in a bead foam molded member that is a cushion member inserted on the side opposite to the seating surface of a resin foam molded product that is a cushioning material for a vehicle seat. .

A first aspect of the present invention is a bead foam molded member for a vehicle seat, which is integrated in a layered manner on the side opposite to the seating surface of a resin foam molded product that is a cushioning material of the vehicle seat, and the bead foam molded member is When viewed from a direction substantially perpendicular to the seating surface, a frame-shaped reinforcing member is inserted into the outer peripheral edge of the bead foam molded member, and is surrounded by the reinforcing member of the bead foam molded member. The region is characterized in that at least one slit-like through hole passing through the region in the thickness direction is provided.

According to the first invention, the tensile stress in the direction substantially parallel to the seating surface of the resin foam molded member due to molding shrinkage of the bead foam molded member is divided by the through hole and reduced, thereby reducing the tensile stress in the direction substantially perpendicular to the seating surface of the resin foam molded product. Deformations such as warping and twisting are suppressed. This allows the surface of the bead foam molded member opposite to the seating surface to be attached more closely to the cavity surface of the upper mold during molding of the resin foam molded product. In addition, it is possible to prevent defects such as underfilling from occurring inside the resin foam molded product.

A second aspect of the present invention is that in the first aspect, the reinforcing member is formed of a metal linear member, and at least one of the through holes is configured to support the bead foam molded member against the seating surface. When viewed from a substantially vertical direction, the reinforcing member is arranged such that its longitudinal direction extends along the reinforcing member.

According to the second aspect of the invention, at least one of the through holes is arranged so that its longitudinal direction extends along the reinforcing member formed from a metal linear member. The bending load applied to the reinforcing member is relaxed, and the reinforcing member is less likely to deform in a direction substantially perpendicular to the seating surface of the resin foam molded body. This suppresses deformation of the bead foam molded member which is increased due to deformation of the reinforcing member.

A third aspect of the present invention is that in the second aspect, the through hole, the longitudinal direction of which is arranged so as to extend along the reinforcing member, extends the bead foam molded member in a direction substantially perpendicular to the seating surface. When viewed from above, the width of the bead foam molded member between the reinforcing member and the through hole is set to be 1 to 5 times the length of the through hole in the short direction. .

According to the third aspect of the invention, the through holes extend along the reinforcing member formed from the linear member and are arranged close to each other, so that the through holes are disposed close to each other so that the reinforcing member is formed from the linear member. Bending deformation of the linear member can be efficiently absorbed, and deformation of the linear member can be suppressed. As a result, deformation of the vehicle seat cushion member that is increased due to deformation of the reinforcing member is efficiently suppressed.

A fourth invention of the present invention is that in any one of the first to third inventions, the bead foam molded member is arranged with respect to the center line in the width direction of the seat when viewed from a direction substantially perpendicular to the seating surface. It is characterized in that it is formed in a left-right symmetrical shape, and that the through holes are arranged in a left-right symmetrical shape with respect to a center line in the width direction of the sheet.

According to the fourth invention, the bead foam molded member is formed to be symmetrical with respect to the center line in the sheet width direction, and the through holes are arranged so as to be symmetrical with respect to the center line in the sheet width direction. Tensile stress caused by molding shrinkage of the bead foam molded member can be suppressed in a well-balanced manner. Thereby, deformation such as warping or twisting of the bead foam molded member in a direction substantially perpendicular to the seating surface of the resin foam molded body can be efficiently suppressed.

FIG. 1 is a perspective view of a cushion pad with an integrated bead foam molded member for a vehicle seat according to a first embodiment of the present invention. It is an exploded perspective view of the cushion pad concerning the above-mentioned embodiment. It is a top view of the cushion pad concerning the said embodiment. 4 is a cross-sectional view taken along line IV-IV in FIG. 3. FIG. 4 is a cross-sectional view taken along line VV in FIG. 3. FIG. FIG. 3 is a cross-sectional view showing a mold for molding the cushion pad according to the above embodiment. A cross section corresponding to FIG. 4 is shown. The cavity is hollow. FIG. 3 is a cross-sectional view showing a mold for molding the cushion pad according to the above embodiment. A cross section corresponding to FIG. 4 is shown. This is a state in which the bead foam molded member is attached to the upper mold. FIG. 2 is a plan view of a cushion pad integrated with a bead foam molded member for a vehicle seat according to a reference example of the present invention. 9 is a cross-sectional view taken along line IX-IX in FIG. 8. FIG. FIG. 2 is a plan view of a cushion pad integrated with a bead foam molded member for a vehicle seat according to a reference example of the present invention. 11 is a cross-sectional view taken along line XI-XI in FIG. 10. FIG. FIG. 7 is a plan view of a cushion pad with an integrated bead foam molded member for a vehicle seat according to a second embodiment of the present invention. 13 is a sectional view taken along line XIII-XIII in FIG. 12. FIG.

A bead foam molded member 20 according to a first embodiment of the present invention will be described with reference to FIGS. 1 to 5 together with a cushion pad 1 that is a cushioning material for an automobile seat formed by integrating the bead foam molded member 20. . In each figure, arrows indicate each direction of the vehicle when the cushion pad 1 is attached to the floor of the vehicle. In the following description, descriptions regarding directions will be made with this direction as a reference.

As shown in FIG. 1, the cushion pad 1 is for a seat cushion for a three-person bench seat, and has a length in the left-right direction that is approximately the same as the width of the vehicle interior. A seat cushion is formed by covering the cushion pad 1 with a cushion cover (not shown) that covers the surface thereof. A rear seat is constructed by combining a seat back (not shown) having a similar configuration and standing upright at the rear end of the seat cushion and attaching it to the floor of the vehicle interior. Here, the cushion pad 1 corresponds to a "resin foam molded product" in the claims.

As shown in FIGS. 1 to 5, the cushion pad 1 has a pair of left and right seat sections 1S, and a center seat section 1C disposed between the left and right seat sections 1S. Further, the cushion pad 1 includes a surface pad 10 arranged on the front side, which is the seating surface side, and a bead foam molded member 20 arranged on the back side, which is the lower side of the surface pad 10.

The surface pad 10 is made of urethane foam formed by foaming polyurethane resin, and its density is set to, for example, about 0.045±0.005 g/cm ³ . The surface pad 10 has a surface portion 11 having a shape and area that occupies the entire surface of the cushion pad 1 on the seating surface side, and a back surface portion 12 forming a part of the cushion pad 1 on the side opposite to the seating surface. As shown in FIG. 4, the surface pad 10 has a buttock support portion 10a that supports the buttocks of the occupant seated in the left and right seat portions 1S, and a buttock support portion 10a that supports the thighs of the occupant seated in the left and right seat portions 1S. It is formed thicker than the thigh support part 10b. This is to improve sitting comfort by more elastically supporting the buttock support part 10a, which has a higher sitting pressure, than the thigh support part 10b, which has a lower sitting pressure. Further, as shown in FIG. 5, in the surface pad 10, the thigh support portions 10d of the center seat portion 1C are formed to be slightly thicker than the thigh support portions 10b of the left and right seat portions 1S. Although not shown, the buttock support portion 10c of the center seat portion 1C is formed thinner than the buttock support portions 10a of the left and right seat portions 1S. As shown in FIG. 3, the surface portion 11 of the surface layer pad 10 has a pair of vertical grooves 11a extending in the front-rear direction on the left and right sides of the left and right seat portions 1S, and a distance between the pair of vertical grooves 11a between the rear end portion and approximately the center in the front-rear direction. Two lateral grooves 11b are formed which are connected at a portion. The vertical groove 11a and the horizontal groove 11b are formed in a substantially U-shape with a cross section opening upward.

The bead foam molded member 20 is a bead foam molded product of olefin resin such as polypropylene or polyethylene, and its density is about 0.03 g/cm ³ . The bead foam molded member 20 is formed to have a lower density and a higher elastic modulus than the surface layer pad 10. The volume of the bead foam molded member 20 is approximately 1/3 of the entire volume of the cushion pad 1.

As shown in FIG. 2, FIG. 4, and FIG. It has a section 22. As shown in FIG. 4, in the bead foam molded member 20, the buttock support portion 20a, which is a portion that supports the buttocks of the occupant seated on the left and right seat portions 1S, is a portion that supports the thighs of the occupant seated on the left and right seat portions 1S. The thigh support portion 20b is formed thinner than the thigh support portion 20b. This is to ensure a predetermined wall thickness of the cushion pad 1 corresponding to the wall thicknesses of the buttock support portion 10a and the thigh support portion 10b of the surface pad 10. The bead foam molded member 20 is provided with a pair of left and right through holes 20c that penetrate in the vertical direction toward the outer sides of the rear portions of the left and right seats 1S in the left and right direction (width direction). Further, the bead foam molded member 20 is provided with one central through hole 20d extending from the rear of the central seat portion 1C to the inner side in the left-right direction (width direction) of the rear portions of the left and right seat portions 1S. As a result, when the surface layer pad 10 is integrally foam-molded with the bead foam molded member 20, a part of the surface layer pad 10 enters the left and right through holes 20c and the center through hole 20d of the bead foam molded member 20, and molds and hardens. Then, an exposed back surface portion 12a, which is a part of the back surface portion 12 of the surface layer pad 10, is formed. The exposed back surface portion 12 a forms the back surface of the cushion pad 1 together with the back surface portion 22 of the bead foam molded member 20 . The front side part 21 of the bead foam molded member 20 is joined to the joining back surface part 12b, which is a part of the back surface part 12 of the surface layer pad 10 other than the exposed back surface part 12a, during integral foam molding of the surface layer pad 10.

As shown in FIGS. 2, 3 to 5, a frame 23 made of iron wire is inserted inside the front, rear, left and right peripheral edges of the bead foam molded member 20. The frame 23 is configured to connect a main frame 23a having a substantially U-shape with an opening at the front when viewed from above, a front frame 23b disposed between the opening sides of the main frame 23a, and connecting the main frame 23a and the front frame 23b. It has two plate-shaped connection frames 23c. Further, the frame 23 includes one rear locking frame 24a and four front locking frames 24b for locking the cushion pad 1 to the vehicle floor. The opening side end of the main frame 23a and the left and right ends of the front frame 23b are connected by welding to the connecting frame 23c. Further, the rear locking frame 24a is fixed by welding to the main frame 23a, and the front locking frame 24b is fixed by welding to the connecting frame 23c. When bead foam molding the bead foam molded member 20, the main frame 23a, the front frame 23b, and the connecting frame 23c formed in a frame shape are placed at predetermined positions in the mold and are integrated by integral foam molding. There is. The frame 23 not only functions as a skeleton, but also has the function of being attracted and held by a magnet embedded in the upper cavity surface when the bead foam molded member 20 is attached to the upper cavity surface of the upper mold when molding the cushion pad 1. also fulfill. Here, the frame 23 corresponds to a "reinforcing member" in the claims.

As shown in FIGS. 3 to 5, the bead foam molded member 20 has three slit-shaped through holes that penetrate in the vertical direction and extend in the left-right direction, and a slit-shaped through hole that penetrates in the vertical direction and extends in the front-back direction. Three through holes are formed. The slit-shaped through hole extending in the left-right direction has one central horizontal through-hole 25 and a pair of left and right horizontal through-holes 26 . The central horizontal through hole 25 has a rounded rectangular cross section cut along a horizontal plane when viewed from above. Then, at a portion where the long axis is slightly forward from the front end of the center through hole 20d, the left side portion of the left and right seat portions 1S on the right side passes through the center seat portion 1C to the right side portion of the left and right seat portions 1S in the left-right direction. It is formed to extend in a straight line. Further, the short axis is set to extend in the front-rear direction by a length comparable to the width of the vertical groove 11a. That is, it has a slit shape in which the ratio of the length of the long axis to the length of the short axis is extremely large. The left and right lateral through holes 26 are provided in pairs symmetrically with respect to the left and right center line of the bead foam molded member 20 when viewed from above, and have a rounded rectangular cross section cut along a horizontal plane. The long axis is located approximately on the extension line in the left-right direction of the front end of the center through hole 20d, and extends from the right end of the right left and right seat portions 1S to the right end of the center seat portion 1C, and the left and right sides. It is formed to extend linearly in the left-right direction from the left end side of the seat portion 1S to the left end side of the center seat portion 1C. Further, the short axis is set to extend in the front-rear direction by a length comparable to the width of the vertical groove 11a. That is, the length of the short axis of the left and right horizontal through holes 26 is set to be equal to the length of the short axis of the central horizontal through hole 25, and the length of the short axis of the left and right horizontal through holes 26 is set to be equal to the length of the short axis, and the length of the short axis is set to be slit-like in which the ratio of the length of the long axis to the length of the short axis is large. has been done. As shown in FIG. 4, an expanded portion 26a whose length in the short axis direction is approximately doubled is formed at the end portion of the left and right lateral through-holes 26 in the direction of the back side portion 22. As will be described later, when the bead foam molded member 20 is held with the back side 22 in contact with the upper cavity surface 42a of the upper mold 42 during the process of molding the cushion pad 1, the expanded portion 26a is formed on the upper cavity surface 42a. It is formed so as to engage with a convex portion 42b provided in the. Due to the engagement between the expanded portion 26a and the convex portion 42b, the foamed urethane resin raw material M is transferred from the left and right lateral through holes 26 between the back side 22 of the bead foam molded member 20 and the upper cavity surface 42a during integral foam molding of the surface layer pad 10. be prevented from invading. Although not shown in the drawings, similarly to the left and right lateral through-holes 26, the central lateral through-hole 25 has an enlarged portion at its end in the direction of the back side 22, which is approximately twice the length in the minor axis direction. There is. The function of this expanded portion is also similar to that of the expanded portion 26a. Here, the central lateral through hole 25 and the left and right lateral through holes 26 correspond to "through holes" in the claims.

As shown in FIGS. 3 to 5, the slit-shaped through hole extending in the front-back direction has one central vertical through hole 27 and a pair of left and right vertical through holes 28. The central vertical through hole 27 has a rounded rectangular cross section cut along a horizontal plane when viewed from above. When viewed from above, the long axis is formed to extend linearly in the front-rear direction between the central lateral through-hole 25 and the front frame 23b on the left-right center line of the bead foam molded member 20. Further, the short axis is set to extend in the left-right direction by a length comparable to the groove width of the vertical groove 11a. That is, it has a slit shape in which the ratio of the length of the long axis to the length of the short axis is large. The left and right vertical through holes 28 are provided as a pair symmetrically with respect to the left and right center line of the bead foam molded member 20 when viewed from above, and have a rounded rectangular cross section cut along a horizontal plane. When viewed from above, the long axis extends linearly in the front-rear direction from the center of the bead foam molded member 20 in the front-rear direction to near the rear end of the connecting frame 23c along the right side of the main frame 23a. . Further, the short axis is set to extend in the left-right direction by a length comparable to the groove width of the vertical groove 11a. That is, the length of the short axis of the left and right vertical through holes 28 is set to be equal to the length of the short axis of the central horizontal through hole 25, and the length of the short axis of the left and right vertical through holes 28 is set to be equal to the length of the short axis of the central horizontal through hole 25. has been done. The right end of the right-hand left and right vertical through-holes 28 is spaced leftward from the left end of the right-hand side of the main frame 23a by about 2 to 3 times the length of the short axis. The left end portion of the main frame 23a is spaced apart from the right end portion of the left side portion of the main frame 23a in the right direction by approximately two to three times the length of the short axis. As shown in FIG. 5, at the ends of the central vertical through-hole 27 and the left and right vertical through-holes 28 in the direction of the back side 22, an expanded part 27a and an expanded part 27a whose length in the short axis direction is approximately doubled, respectively. An opening 28a is formed. The functions of the expanded portion 27a and the expanded portion 28a are also similar to the expanded portion 26a of the left and right lateral through holes 26 described above. Here, the central vertical through hole 27 and the left and right vertical through holes 28 correspond to "through holes" in the claims.

A method for manufacturing the cushion pad 1 will be described based on FIGS. 6 and 7. Note that the directions shown in FIGS. 6 and 7 correspond to the direction of the cushion pad 1. The bead foam molded member 20 is molded by bead foam molding of olefin resin with the frame 23 inserted in advance. Bead foam molding is a method of pre-foaming raw material beads, which are olefin resin pellets impregnated with a blowing agent, into a mold cavity and heating them with steam to further expand the pre-foam beads. This is a molding method that creates a shape that follows the mold cavity. Specifically, a first mold (not shown) having a cavity surface corresponding to the shape of the front side part 21 of the bead foam molded member 20 and a cavity corresponding to the shape of the back side part 22 of the bead foam molded member 20 are used. A second mold (not shown) having a surface is used. Then, when the second mold is closed with respect to the first mold, the frame 23 is set in the cavity formed between the molds, and pre-foamed beads are filled with the pre-foamed beads and heated with steam. The beads are further expanded and shaped to fit the cavity. Note that the parts of the mold forming the central horizontal through hole 25, the left and right horizontal through holes 26, the central vertical through hole 27, and the left and right vertical through holes 28 are provided so as to stand up from the cavity surface of the second mold. ing.

Next, the cushion pad 1 is formed by integrally foaming the surface layer pad 10 with the bead foam molded member 20. As shown in FIG. 6, the urethane foam mold 40 for molding the cushion pad 1 is composed of a lower mold 41 and an upper mold 42 that can be opened and closed with respect to the lower mold 41. Both the lower mold 41 and the upper mold 42 are equipped with a mold temperature control function for molding urethane foam resin and a locking mechanism (not shown) when the molds are closed. The lower mold 41 is formed with a lower cavity surface 41a having a shape corresponding to the surface portion 11 of the surface layer pad 10, which is the shape of the surface side of the cushion pad 1. The upper mold 42 is formed with an upper cavity surface 42 a having a shape corresponding to the back surface 22 of the bead foam molded member 20 and the exposed back surface 12 a of the surface pad 10 , which are the back surface shapes of the cushion pad 1 . With the upper mold 42 closed to the lower mold 41, a cavity 43 surrounded by a lower cavity surface 41a and an upper cavity surface 42a is formed between the lower mold 41 and the upper mold 42. As shown in FIG. 7, the back side 22 of the bead foam molded member 20 is brought into contact with the upper cavity surface 42a of the upper die 42 and held therein. A plurality of permanent magnets (not shown) that magnetically attract and hold the frame 23 inserted into the bead foam molded member 20 are embedded at predetermined positions in the upper cavity surface 42a. The bead foam molded member 20 is held on the upper cavity surface 42a by this magnetic force and the uneven fitting between the back side portion 22 and the upper cavity surface 42a. The state shown in FIG. 7 is a state in which the upper mold 42 to which the bead foam molded member 20 is attached is closed with respect to the lower mold 41. At this time, since the bead foam molded member 20 is restrained from deforming in a direction substantially perpendicular to the seating surface of the cushion pad 1, it can be attached with the back side portion 22 in close contact with the upper cavity surface 42a. . In this state, as shown in FIG. 7, before closing the upper mold 42 with respect to the lower mold 41, the foamed urethane resin raw material M is introduced onto the lower cavity surface 41a of the lower mold 41 and the mold is closed. Then, the foamed urethane resin raw material M foams and fills the cavity 43 while increasing its volume, and after a predetermined time for foaming and curing has elapsed, the surface layer pad 10 is formed. As a result, the surface pad 10 is formed and is integrated with the bead foam molded member 20 to manufacture the cushion pad 1. Thereafter, the upper mold 42 is opened relative to the lower mold 41 and the molded cushion pad 1 is removed from the mold.

The first embodiment configured as described above has the following effects. The tensile stress in the direction substantially parallel to the seating surface due to molding shrinkage of the bead foam molded member 20 is divided by the central horizontal through hole 25, the left and right horizontal through holes 26, the central vertical through hole 27, and the left and right vertical through holes 28, and is reduced. Become. This suppresses deformation such as warping or twisting of the cushion pad 1 in a direction substantially perpendicular to the seating surface. Then, when molding the cushion pad 1, it becomes possible to attach the back side 22 of the bead foam molded member 20 in closer contact with the upper cavity surface 42a. The occurrence of defects can be suppressed. In addition, since the left and right vertical through holes 28 are arranged so that their longitudinal directions extend along the frame 23, the bending load applied to the frame 23 due to mold shrinkage of the bead foam molded member 20 is alleviated, and the frame 23 is The cushion pad 1 is less likely to deform in a direction substantially perpendicular to the seating surface. This suppresses the deformation of the bead foam molded member 20 that is increased due to the deformation of the frame 23. Further, since the left and right vertical through holes 28 extend along the frame 23 in the longitudinal direction and are arranged close to each other, bending deformation of the frame 23 due to molding shrinkage of the bead foam molded member 20 can be efficiently absorbed. 23 can be suppressed from deformation. In addition, the bead foam molded member 20 is formed in a symmetrical shape with respect to the center line in the sheet width direction, and the central horizontal through hole 25, the left and right horizontal through holes 26, the central vertical through hole 27, and the left and right vertical through holes 28 are formed in the sheet. They are arranged symmetrically with respect to the center line in the width direction. As a result, the tensile stress caused by the molding shrinkage of the bead foam molded member 20 can be suppressed in a well-balanced manner, and deformations such as warpage and twisting in a direction substantially perpendicular to the seating surface of the cushion pad 1 of the bead foam molded member 20 can be efficiently prevented. It can be suppressed.

8 and 9 show a cushion pad 1A, which is a cushioning material for an automobile seat, which is formed by integrating a bead foam molded member 20A, which is a reference example of the present invention. Structures common to those in the first embodiment are given corresponding symbols and detailed explanations are omitted. The difference from the first embodiment is that the main frame 23a of the frame 23 is formed by a combination of one rear frame 23a1 and a pair of left and right frames 23a2 to form a frame 23A, and that a pair of left and right vertical through holes 28 are formed. This is because there are a pair of left and right vertical through holes 28A at different positions. The frame 23A includes a main frame 23a of the frame 23, a substantially U-shaped rear frame 23a1 made of iron wire that opens toward the front in the rear portion, and a connection frame 23c between the front end of the rear frame 23a1 and the connecting frame 23c. It is formed by being replaced by a combination frame with a pair of left and right frames 23a2 made of iron wire that open toward the inner side of the seats to be connected. The pair of left and right frames 23a2 are disposed at positions projecting outward in the seat width direction from the longitudinal grooves 11a on the outside in the seat width direction of the cushion pad 1A when viewed from above. The pair of left and right vertical through-holes 28A are disposed inward in the seat width direction from the longitudinal grooves 11a on the outside in the seat width direction of the cushion pad 1A when viewed from above, with their long axes extending in the front-rear direction. The shape of the pair of left and right vertical through-holes 28A in a top view is almost the same as the pair of left and right vertical through-holes 28, but their longitudinal directions extend along the frame 23 and are not arranged closely. Note that, similarly to the central vertical through-hole 27, expanded portions 28Aa are formed at the ends of the pair of left and right vertical through-holes 28A in the direction of the back side 22, respectively. Here, the cushion pad 1A and the frame 23A correspond to a "resin foam molded product" and a "reinforcing member" in the claims, respectively. Further, the left and right vertical through holes 28A correspond to "through holes" in the claims.

In the bead foam molded member 20A, which is a reference example of the present invention, the left and right vertical through holes 28A are not arranged so as to extend in the longitudinal direction along the frame 23, compared to the first embodiment. The effect of reducing the bending load applied to the frame 23 due to molding shrinkage and making it difficult for the frame 23 to deform in a direction substantially perpendicular to the seating surface of the cushion pad 1 is not achieved. Other effects are the same as those of the first embodiment.

10 and 11 show a cushion pad 1B, which is a cushioning material for an automobile seat, which is formed by integrating a bead foam molded member 20B, which is a reference example of the present invention. Structures common to those in the first embodiment are given corresponding symbols and detailed explanations are omitted. The difference from the first embodiment is that the structure of the frame 23 is different and that it is a frame 23B, and that the positions and shapes of the through holes are different. The frame 23B has an approximately U-shaped main frame 23a3 made of iron wire that is open at the front when viewed from above, and a front frame 23b1 that is approximately U-shaped and made from iron pipe that is open from the rear when viewed from above. It is a frame shaped like a frame with parts connected to each other. A pair of left and right front locking frames 24b1 are attached to the front frame 23b1. As for the through-holes and through-holes, as viewed from above, they are arranged symmetrically with respect to the left-right center line of the bead foam molded member 20B, so the through-holes and through-holes on the right side will be explained as a representative, and the through-holes and through-holes on the left side will be explained as a representative. Description of the holes will be omitted. A left and right rear through hole 20f is provided in the vicinity of the right rear corner of the bead foam molded member 20B, a left and right middle through hole 20g is provided in the center of the left and right seats 1S in the longitudinal direction, and a center rear through hole is provided at the rear of the center seat 1C. 20h, a central through hole 20i is provided in the central portion of the central seat portion 1C in the front-rear direction. The first left and right vertical through holes 28B1 are arranged along the left side of the joint between the right main frame 23a3 and the front frame 23b1. The width of the bead foam molded member between the main frame 23a3, the front frame 23b1, and the first left and right vertical through holes 28B1 is set to be approximately the same as the groove width of the vertical groove 11a. The second left and right vertical through holes 28B2 are arranged to extend in the front and back direction from the vicinity of the left rear end of the left and right middle through holes 20g to the main frame 23a3. The third left and right vertical through holes 28B3 are arranged at the left front ends of the left and right middle through holes 20g so as to communicate with the left and right middle through holes 20g and extend forward. The first central vertical through hole 27B1 is arranged to extend in the front-rear direction between the vicinity of the right rear end of the central intermediate through hole 20i and the rear central through hole 20h. The second central vertical through hole 27B2 is disposed at the front right corner of the central central through hole 20i so as to communicate with the central central through hole 20i and extend forward. The first left and right vertical through holes 28B1 are formed into a rectangular shape with rounded corners and a curved cross section when viewed from above on a horizontal plane, and the length of the short axis thereof is set to be approximately the same as the width of the vertical groove 11a. . The second left and right vertical through holes 28B2, the third left and right vertical through holes 28B3, the first central vertical through holes 27B1, and the second central vertical through holes 27B2 are also formed in a rounded rectangular cross section when viewed from above on a horizontal plane. , the length of its short axis is set to be approximately the same as the width of the vertical groove 11a. In addition, at the ends of the first left and right vertical through holes 28B1, the second left and right vertical through holes 28B2, the third left and right vertical through holes 28B3, the first central vertical through holes 27B1, and the second central vertical through holes 27B2 in the direction of the back side 22. In each case, an enlarged portion is formed similarly to the first embodiment. Here, the cushion pad 1B and the frame 23B correspond to a "resin foam molded product" and a "reinforcing member" in the claims, respectively. In addition, the first left and right vertical through holes 28B1, the second left and right vertical through holes 28B2, the third left and right vertical through holes 28B3, the first central vertical through holes 27B1, and the second central vertical through holes 27B2 are Corresponds to "hole".

The bead foam molded member 20B, which is a reference example of the present invention, has the same effects as the first embodiment. Since the first left and right vertical through holes 28B1 are arranged so that their longitudinal direction extends along the frame 23B, the bending load applied to the frame 23B due to molding shrinkage of the bead foam molded member 20 is alleviated, and the frame 23B is The cushion pad 1 is less likely to deform in a direction substantially perpendicular to the seating surface.

12 and 13 show a cushion pad 1D which is a cushioning material for an automobile seat and is formed by integrating a bead foam molded member 20D according to a second embodiment of the present invention. Structures common to those in the first embodiment are given corresponding symbols and detailed explanations are omitted. The difference from the first embodiment is that the positions and shapes of the through holes are different. Regarding the through-holes, since they are arranged symmetrically with respect to the left-right center line of the bead foam molded member 20D when viewed from above, the through-holes and through-holes on the right side will be explained as a representative, and the through-holes and through-holes on the left side will be explained as a representative. Description of the holes will be omitted. In the bead foam molded member 20D, a left and right middle and rear through hole 20j is provided from the center in the front and back direction of the left and right seat portions 1S to the rear, and a center and middle back through hole 20k is provided from the center in the front and back direction of the center seat portion 1C to the rear. There is. The left and right vertical through-holes 28D are only slightly shorter in length in the major axis direction than the left and right vertical through-holes 28 of the first embodiment, and the positions and shapes of the left and right vertical through-holes are almost the same. The length of the central vertical through hole 27D in the major axis direction is only slightly shorter than that of the central vertical through hole 27 of the first embodiment, and the arrangement position and shape are almost the same. The first left and right lateral through-holes 26D1 are arranged to extend in the left-right direction at a portion slightly forwardly away from the front end portions of the left and right middle and rear through holes 20j. The second left and right lateral through holes 26D2 are arranged to extend in the left and right direction so as to intersect with the vertical grooves 11a on the inner side in the seat width direction at substantially the same location in the front and back direction as the first left and right lateral through holes 26D1. The first left and right horizontal through holes 26D1 and the second left and right horizontal through holes 26D2 are formed in a rectangular cross section with rounded corners when viewed from above on a horizontal plane, and the length of the short axis thereof is the same as the groove width of the vertical groove 11a. It is set to about. The lengths of the first left and right horizontal through-holes 26D1 and the second left and right horizontal through-holes 26D2 in the longitudinal direction are approximately equal and about ⅓ of the interval between the vertical grooves 11a. Note that the end portions of the left and right vertical through holes 28D, the central vertical through hole 27D, the first left and right horizontal through holes 26D1, and the second left and right horizontal through holes 26D2 in the direction of the back side 22 are respectively enlarged in the same way as in the first embodiment. An opening is formed. Here, the cushion pad 1D corresponds to a "resin foam molded product" in the claims. Further, the left and right vertical through holes 28D, the central vertical through hole 27D, the first left and right horizontal through holes 26D1, and the second left and right horizontal through holes 26D2 correspond to "through holes" in the claims.

The bead foam molded member 20D, which is the second embodiment of the present invention, has the same effects as the first embodiment. Since the left and right vertical through holes 28D are arranged so that their longitudinal directions extend along the frame 23D, the bending load applied to the frame 23D due to the molding shrinkage of the bead foam molded member 20D is alleviated, and the frame 23D becomes a cushion pad. It becomes difficult to deform in a direction substantially perpendicular to the seating surface of No. 1.

Although 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. Examples include:

1. In the above embodiment, bead foam molded articles of olefin resin such as polypropylene and polyethylene are used as the bead foam molded members 20, 20A, 20B, and 20D, but the invention is not limited to this. It is also possible to use a bead foam molded product of a composite resin with a resin.

2. In the above embodiment, the present invention is applied to a seat cushion for an automobile, but it may also be applied to a seat back for an automobile, or to a seat mounted on an airplane, a ship, a train, etc.

1, 1A, 1B, 1D Cushion pad (resin foam molding)
10 Surface pad 11 Surface portion (seating surface)
12 Back part 20, 20A, 20B, 20D Bead foam molded member 21 Front part 22 Back part 23, 23A, 23B, 23D Frame (reinforcing member)
25 Central horizontal through hole (through hole)
26 Left and right horizontal through holes (through holes)
26D1 1st left and right horizontal through hole (through hole)
26D2 2nd left and right horizontal through hole (through hole)
27 Center vertical through hole (through hole)
27B1 First central vertical through hole (through hole)
27B2 Second central vertical through hole (through hole)
27D Center vertical through hole (through hole)
28 Left and right vertical through holes (through holes)
28A Left and right vertical through holes (through holes)
28B1 1st left and right vertical through hole (through hole)
28B2 2nd left and right vertical through hole (through hole)
28B3 3rd left and right vertical through hole (through hole)
28D Left and right vertical through holes (through holes)
40 Urethane foam mold 41 Lower mold 41a Lower cavity surface 42 Upper mold 42a Upper cavity surface 43 Cavity M Urethane foam resin raw material

Claims (3)

A bead foam molded member for a vehicle seat that is integrated in a layered manner on the side opposite to the seating surface of a resin foam molded product that is a cushioning material for the vehicle seat,
When the bead foam molded member is viewed from a direction substantially perpendicular to the seating surface, a frame-shaped reinforcing member is inserted into the outer peripheral edge of the bead foam molded member,
In the area surrounded by the reinforcing member of the bead foam molded member, there are at least one slit-like through hole extending in the sheet width direction and at least one slit -like through hole extending in the direction perpendicular to the sheet width direction. It is provided,
The reinforcing member is formed from a metal linear member,
At least one of the through holes is a bead for a vehicle seat, the longitudinal direction of which extends along the reinforcing member when the bead foam molded member is viewed from a direction substantially perpendicular to the seating surface. Foam molded parts. In claim 1, the through hole, which is arranged so that its longitudinal direction extends along the reinforcing member, is not connected to the reinforcing member when the bead foam molded member is viewed from a direction substantially perpendicular to the seating surface. A bead-foamed molded member for a vehicle seat, wherein the width of the bead-foamed molded member between the through-hole and the through-hole is set to 1 to 5 times the length of the through-hole in the short direction. In claim 1 or claim 2, the bead foam molded member is formed to be symmetrical with respect to a center line in the seat width direction when viewed from a direction substantially perpendicular to the seating surface, and the through hole is formed in a shape that is symmetrical with respect to a center line in the seat width direction. A bead-foamed molded member for a vehicle seat arranged so as to be symmetrical with respect to a directional center line.

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