JP7404980B2 - Components of vehicle seats and molds thereof - Google Patents

Description

The present invention relates to a component of a vehicle seat and a mold thereof.

Conventionally, in automobile seats, seat cushions or seat backs are formed by placing a seat component made by integrally foaming a pad body, which is a cushioning material, on an upholstery material, and placing it on a frame as a skeleton. There is something that has been done. FIG. 7 shows a cross section of a portion of this sheet component 100. The seat component 100 includes a first piece 111, which is one of a plurality of pieces forming the skin material 110, and a second piece 112, which are sewn together along a sewing line 113, and a pad made of urethane foam is attached to the back side of the first piece 111, which is one of the plurality of pieces forming the skin material 110, and a second piece 112, which are sewn together along a sewing line 113. The body 120 is integrated by integral foam molding. The first piece 111 and the second piece 112 are formed by cutting a layered body in which a fabric 110A and a urethane slab pad 110B are laminated. The first piece 111 and the second piece 112 each have main parts 111a and 112a, and standing wall parts 111b and 112b vertically rising from the main parts 111a and 112a. On the urethane slab pad 110B side of the corner parts 111c and 112c between the main parts 111a and 112a and the standing wall parts 111b and 112b, there are inset parts 111d and 112d in which a part of the urethane slab pad 110B is recessed in the direction of the fabric 110A. is formed. This is because the surface of the urethane slab pad 110B on the pad body 120 side is fitted in the direction of the fabric 110A in order to ensure the cross-sectional circumference at the corner portions 111c and 112c. On the side of the skin material 110 opposite to the fabric 110A of the urethane slab pad 110B, a highly hard impregnated layer 110C is formed in which a part of the raw material penetrates and solidifies during the integral foam molding process of the pad body 120. . Note that a similar configuration is described in Patent Document 1.

JP 2017-81219 Publication

In the above-described sheet component 100, as shown in FIG. 7, the impregnated layer 110C is also formed on the urethane slab pad 110B of the insertion portions 111d and 112d in the skin material 110. This impregnated layer 110C has a higher hardness than the urethane slab pad 110B, and is arranged closer to the fabric 110A than the main parts 111a and 112a in the insertion parts 111d and 112d. As a result, an occupant seated on the fabric 110A of the main portions 111a, 112a of the skin material 110 feels uncomfortable about the corner portions 111c, 112c, which poses a problem. Therefore, as shown in FIG. 8, a resin tape 150 was attached to cover the standing wall portions 111b and 112b from the insertion portions 111d and 112d. When the resin tape 150 is pasted, the impregnated layer 110C is not formed on the urethane slab pad 110B in that area, so the discomfort of hardness can be avoided, but there is a problem in that the material cost increases.

In view of these problems, an object of the present invention is to provide a seat component and a mold thereof, in which a pad body is integrally foam-molded with a skin material, and the feeling of discomfort at the sewing line portion of the skin material is suppressed.

A first aspect of the present invention relates to a component of a vehicle seat, in which a pad body serving as a cushioning material and a skin material covering the pad body are integrated during foam molding of the pad body. The skin material is configured by laminating a surface layer portion disposed on the seating surface side and a foam layer portion laminated on the opposite side of the surface layer portion to the seating surface. Further, the skin material is formed by integrating a plurality of pieces by sewing. Adjacent first and second pieces among the plurality of pieces are connected by a sewing line. The first piece has a first main portion forming a seating surface and a first vertical wall portion extending from the first main portion in a direction away from the seating surface. The second piece has a second main portion forming a seating surface and a second standing wall portion extending from the second main portion in a direction away from the seating surface. The first vertical wall portion and the second vertical wall portion are provided with the sewing line with their surface layer portions facing each other. A surface of the foam layer portion of the first main portion on the pad body side and a surface of the foam layer portion of the first vertical wall portion on the pad body side intersect at an acute angle without a gap. Further, a surface of the foam layer portion of the second main portion on the pad body side and a surface of the foam layer portion of the second vertical wall portion on the pad body side intersect at an obtuse angle.

According to the first invention, the surface of the foam layer portion of the first main portion on the pad body side and the surface of the foam layer portion of the first vertical wall portion on the pad body side intersect at an acute angle without a gap. In other words, between the foam layer portion of the first main portion and the foam layer portion of the first vertical wall portion, the opening side of the insertion portion where a portion of the foam layer portion is recessed toward the surface layer portion is closed. Moreover, since the foam layer parts intersect at an obtuse angle between the foam layer part of the second main part and the foam layer part of the second vertical wall part, no fitting part is formed. This prevents the gap between the surface layer and the impregnated layer, which is formed by part of the raw material from penetrating and solidifying during the process of integral foam molding of the pad body into the foam layer, from becoming too narrow, resulting in the structure of the vehicle seat. It is possible to suppress deterioration of the feeling on the seating surface of the member.

A second aspect of the present invention relates to a mold for forming a component of a vehicle seat according to the first aspect. a lower mold in which the skin material is arranged such that the surface layer portion contacts a mold surface; and a pad body having a surface shape on the opposite side of the skin material of the pad body when closed with respect to the lower mold. an upper mold forming a cavity corresponding to the mold. A plate-shaped vertical plate part inserted between the first vertical wall part and the second vertical wall part is formed on the mold surface of the lower mold, and forms an acute angle with respect to the main mold surface that contacts the first main part. They are disposed so as to intersect at an obtuse angle with respect to the main mold surface that abuts the second main portion.

According to the second invention, the first main part and the second main part are brought into contact with the main mold surface of the lower mold, and the first standing wall part and the second standing wall part are brought into contact with each other so as to sandwich the standing plate part. In this state, the upper mold is closed and a molding material for forming a pad body is injected into the cavity, thereby forming a component of a vehicle seat.

FIG. 2 is a perspective view of the automobile seat viewed diagonally from the front. FIG. 2 is a sectional view taken along the line II-II of the component of the automobile seat shown in FIG. 1; FIG. 3 is an enlarged view of part III in FIG. 2; It is a figure explaining the integration process of a skin material and a pad body. Shows the skin material attached to the mold. It is a figure explaining the integration process of a skin material and a pad body. This figure shows the state in which the mold material for the pad body is injected and the mold is closed. It is a figure explaining the integration process of a skin material and a pad body. The pad body is cured in the mold and the skin material and the pad body are integrated. FIG. 2 is a diagram illustrating a conventional technique. FIG. 2 is a diagram illustrating a conventional technique.

1-6 illustrate one embodiment of the invention. This embodiment is an example in which the present invention is applied to an automobile seat 1. In each figure, arrows indicate directions of the automobile seat 1 and the automobile when the automobile seat 1 is attached to the automobile. In the following description, descriptions regarding directions will be made with this direction as a reference. The automobile seat 1 of this embodiment includes a seat cushion 2 serving as a seating portion and a seat back 3 serving as a backrest. Here, the automobile seat 1 corresponds to a "vehicle seat" in the claims.

As shown in FIG. 1, the seat cushion 2 includes a cushion frame (not shown) forming a skeleton, and a cushion component 10 placed on the cushion frame. The cushion component 10 includes a cushion pad 11 that is a cushion material and a cushion cover 12 that is a skin material (see FIG. 2). The seat back 3 includes a back frame (not shown) that forms a skeleton, a back pad (not shown) that is a cushion material placed on the back frame, and a back cover that is a skin material that covers the back pad. 3a. Since the seat back 3 has a normal configuration, further explanation will be omitted, and the cushion component 10 of the seat cushion 2 having a unique configuration will be described. Here, the cushion component 10, the cushion pad 11, and the cushion cover 12 correspond to the "component", "pad body", and "skin material" in the claims, respectively.

As shown in FIGS. 1 and 2, the cushion cover 12 is formed by sewing a plurality of pieces into a bag shape that opens downward. Specifically, the cushion cover 12 includes a top plate main portion 12a that supports the lower surface side of the buttocks and thighs of the seated person, and a top plate main portion 12a that is located on both left and right sides of the top plate main portion 12a and mainly supports the seated person's buttocks and thighs. It has a top plate side portion 12b that supports the side surface of the thigh. Further, the cushion cover 12 has side portions 12c that are located on the outer side in the seat width direction of the left and right top plate side portions 12b and cover the bank portions 11b of the cushion pad 11 that protrude upward. The top plate main portion 12a and the top plate side portions 12b are sewn along a sewing line L1 extending substantially in the front-rear direction. The top plate side portion 12b and the side portion 12c are sewn along a sewing line L2 extending substantially in the front-rear direction. The top plate main portion 12a, the top plate side portions 12b, and the side portions 12c correspond to each piece. The top plate main part 12a and the top plate side part 12b correspond to the "first piece" and "second piece" in the claims, respectively.

As shown in FIG. 3, the plurality of pieces constituting the cushion cover 12 include a surface layer portion 12A disposed on the front side and a foam layer portion disposed on the back side (opposite to the front side) of the surface layer portion 12A. 12B is cut from a laminated layered body. Specifically, as the surface layer portion 12A, cloth such as fabric, genuine leather, synthetic leather, or the like is preferably used. Further, the foam layer portion 12B is made of slab urethane having a low air permeability (about 1 to 10 cc/cm ² ·sec). The foam layer part 12B is made of slab urethane with high air permeability (about 200 to 400 cc/cm ² ·sec) on the side of the surface layer part 12A, and low air permeability (1 to 10 cc/cm ² · on the opposite side to the surface layer part 12A). It is also possible to have a double structure in which a slab urethane (about 100 sec) is laminated. The foam layer portion 12B prevents the molding material M (see FIG. 5) of the cushion pad 11 from reaching the surface layer portion 12A during foam molding of the cushion pad 11, and contributes to giving the cushion cover 12 a soft feel.

As shown in FIG. 2, the cushion pad 11 is a member forming the outer shape of the seat cushion 2, and includes a main part 11a corresponding to the top plate main part 12a and the top plate side part 12b of the cushion cover 12, and a main part 11a corresponding to the top plate main part 12a and the top plate side part 12b of the cushion cover 12. It has a bank part 11b corresponding to the side part 12c. The cushion pad 11 is made of polyurethane foam with a density of 10 to 60 kg/m ³ , and a backing material 11c made of nonwoven fabric is integrally attached to the back side opposite to the cushion cover 12.

As shown in FIG. 3, the top plate main portion 12a includes a main main portion 12a1 that forms a seating surface, and a main vertical wall portion 12a2 that stands obliquely downward at an acute angle with respect to the main main portion 12a1. It is formed. The top plate side portion 12b is formed with a side main portion 12b1 that constitutes a seating surface, and a side vertical wall portion 12b2 that stands obliquely downward at an obtuse angle with respect to the side main portion 12b1. The main standing wall portion 12a2 and the side standing wall portion 12b2 are connected by sewing along a sewing line L1 near their tips.

In the corner part 12a3 between the main main part 12a1 and the main vertical wall part 12a2 in the top plate main part 12a, the foam layer part 12B of the main main part 12a1 and the foam layer part 12B of the main vertical wall part 12a2 are bent at an acute angle. It is touching. A fitting part that fits in the direction of the surface layer part 12A is not formed between the foam layer part 12B of the main main part 12a1 and the foam layer part 12B of the main vertical wall part 12a2, and they abut without a gap. A line of contact 12a4 is formed at a position spaced apart from the contact line 12a4. As a result, a part of the molding material M, which is the raw material, enters and solidifies during the process of integrally foam-molding the cushion pad 11 with respect to the foam layer portion 12B, thereby forming a highly hard impregnated layer 12C and a surface layer portion 12A. It is possible to suppress deterioration of the tactile sensation on the seating surface without making the interval too narrow. Here, the main main portion 12a1 and the main vertical wall portion 12a2 correspond to a “first main portion” and a “first vertical wall portion” in the claims, respectively.

In the corner part 12b3 between the side main part 12b1 and the side vertical wall part 12b2 in the top plate side part 12b, the foam layer part 12B of the side main part 12b1 and the foam layer part 12B of the side vertical wall part 12b2 are bent at an obtuse angle. It is touching. The foam layer portion 12B of the side main portion 12b1 and the foam layer portion 12B of the side vertical wall portion 12b2 do not have a fitting portion that smoothly and continuously fits in the direction of the surface layer portion 12A, and the thickness of the foam layer portion 12B is maintained. This prevents the distance between the impregnated layer 12C and the surface layer portion 12A from becoming too narrow, and can prevent the feeling on the seating surface from worsening. Here, the side main part 12b1 and the side standing wall part 12b2 correspond to a "second main part" and a "second standing wall part" in the claims, respectively.

As shown in FIG. 2, the portion of the sewing line L2 where the top plate side portion 12b and the side portion 12c are connected has the same configuration, and has the same effect. The main part 12a of the top plate in the sewing line L1 is simply replaced with the side part 12c, so a description thereof will be omitted. The terminal side of the side portion 12c is fixed to the back side of the cushion pad 11 by adhesive.

A method for manufacturing the cushion component 10 will be described based on FIGS. 4 to 6. The cushion component 10 is manufactured by molding the cushion pad 11 in a mold 20 and simultaneously integrating it with the cushion cover 12. The mold 20 includes a lower mold 21 and an upper mold 22 that forms a cavity 23 shaped in accordance with the shape of the cushion pad 11 therebetween when the mold 20 is closed to the lower mold 21 .

The cavity surface 21a of the lower mold 21 is formed in a shape corresponding to the shape of the upper (seating surface side) surface of the cushion pad 11. Then, the sewing line L1 of the cushion cover 12 is arranged at the apex thereof, and the plate shape extending approximately in the front-rear direction is arranged so as to be sandwiched between the surface layer part 12A of the main vertical wall part 12a2 and the surface layer part 12A of the side vertical wall part 12b2 on both sides. A standing plate portion 21a2 is provided. Specifically, the upright plate portion 21a2 is arranged to intersect at an acute angle with the inner surface of the seat on the main mold surface 21a1, which is a surface corresponding to the upper side (seating surface side) of the cushion component 10 on the cavity surface 21a. It is set up. Further, the upright plate portion 21a2 intersects at an obtuse angle with the surface of the main mold surface 21a1 on the outside of the seat (the surface that the surface layer portion 12A of the side main portion 12b1 comes into contact with when the cushion cover 12 is set on the lower mold 21). It is arranged like this. A raised plate portion 21a3 similar to the raised plate portion 21a2 is also provided in a portion of the cushion cover 12 corresponding to the sewing line L2 and extends in the front-rear direction. The upright plate portion 21a3 is arranged so as to form an acute angle and intersect with the surface of the main mold surface 21a1 on the outside of the sheet. Further, the upright plate portion 21a3 intersects at an obtuse angle with the inner surface of the seat on the main mold surface 21a1 (the surface that the surface layer portion 12A of the side main portion 12b1 comes into contact with when the cushion cover 12 is set on the lower mold 21). It is arranged like this. The cavity surface 22a of the upper mold 22 is formed in a shape corresponding to the shape of the lower side (opposite side to the seating surface) of the cushion pad 11.

As shown in FIG. 4, the cushion cover 12 is set so that the surface layer 12A of the cushion cover 12 is in contact with the cavity surface 21a of the lower mold 21, and the backing material 11c is set on the cavity surface 22a of the upper mold 22. The cushion cover 12 is arranged such that the sewing line L1 is arranged at the apex of the standing plate part 21a2, and both sides are sandwiched between the surface layer part 12A of the main standing wall part 12a2 and the surface layer part 12A of the side standing wall part 12b2. The portion corresponding to the sewing line L2 is arranged in the same manner as the portion corresponding to the sewing line L1 with respect to the standing plate portion 21a3. At this time, the left and right corner parts 12a3 are pressed against the base of the upright plate part 21a2 by the main body part 12a1, so there is no need to temporarily fix the surface part 12A of the cushion cover 12 to the cavity surface 21a with adhesive or the like. do not have. The same applies to the portion corresponding to the sewing line L2. The side portion 12c of the cushion cover 12 is folded halfway toward the outside of the seat and placed on the parting surface 21b.

Next, as shown in FIG. 5, the molding material M is injected onto the foam layer portion 12B of the cushion cover 12 placed on the lower mold 21, and the upper mold 22 is closed with respect to the lower mold 21. At this time, a portion of the side portion 12c of the cushion cover 12 is sandwiched between the parting surface 21b of the lower mold 21 and the parting surface 22b of the upper mold 22. The molding material M is filled into the cavity 23 while foaming and expanding, and is cured in that state as shown in FIG. 6, whereby the cushion pad 11 is molded and simultaneously integrated with the cushion cover 12. At this time, a part of the molding material M enters the foamed layer portion 12B and hardens to form a highly hard impregnated layer 12C. Furthermore, the molding material M is cured in a state in which the backing material 11c also enters, and the backing material 11c is integrated with the cushion pad 11. In this state, open the upper mold 22 with respect to the lower mold 21, take out the cushion pad 11 integrated with the cushion cover 12 from the lower mold 21, and insert the end side of the side part 12c of the cushion cover 12 into the back surface of the cushion pad 11. The cushion component 10 is obtained by fixing to the side by adhesive.

The embodiment configured as described above has the following effects. The surface of the foamed layer portion 12B of the main body portion 12a1 on the cushion pad 11 side and the surface of the foamed layer portion 12B of the main vertical wall portion 12a2 on the cushion pad 11 side intersect at an acute angle without a gap. In other words, between the foam layer portion 12B of the main body portion 12a1 and the foam layer portion 12B of the main vertical wall portion 12a2, the opening side of the insertion portion where a portion of the foam layer portion 12B is recessed toward the surface layer portion 12A is Closed. Furthermore, no fitting portion is formed between the foam layer portion 12B of the side main portion 12b1 and the foam layer portion 12B of the side vertical wall portion 12b2 since the foam layer portions 12B intersect at an obtuse angle. This prevents the distance between the impregnated layer 12C, which is formed by a part of the molding material M from penetrating and solidifying during the integral foam molding process of the cushion pad 11 into the foam layer part 12B, from becoming too narrow, and the surface layer part 12A. Deterioration of the tactile sensation on the seating surface of the cushion component 10 can be suppressed.

In addition, in the mold 20 of the cushion component 10, the main main part 12a1 and the side main part 12b1 are brought into contact with the main mold surface 21a1 of the lower mold 21, and the surface layer of the main vertical wall part 12a2 is made to sandwich the vertical plate part 21a2. The cushion cover 12 is placed in a state where the portion 12A and the surface layer portion 12A of the side vertical wall portion 12b2 are in contact with each other. At this time, the left and right corner parts 12a3 are pressed against the base of the upright plate part 21a2 by the main body part 12a1, so there is no need to temporarily fix the surface part 12A of the cushion cover 12 to the cavity surface 21a with adhesive or the like. do not have. In this state, the cushion component 10 can be molded by injecting the molding material M for forming the cushion pad 11 into the cavity 23.

Although specific embodiments have been described above, the present invention is not limited to their appearance and configuration, and various changes, additions, and deletions can be made without changing the gist of the present invention. Examples include:

1. In the above embodiment, in the process shown in FIG. 5, the molding material M is poured onto the cushion cover 12 placed on the cavity surface 21a of the lower mold 21, and then the upper mold 22 is closed and foam molding is performed. . However, the present invention is not limited to this, and after arranging the cushion cover 12 on the lower mold 21, the upper mold 22 may be closed, and the molding material M may be injected into the cavity 23 through the injection hole in this state.

2. In the above embodiment, the present invention was applied to the seat cushion 2 of the automobile seat 1, but it can also be applied to a seat back. Furthermore, it may be applied to seats mounted on airplanes, ships, trains, etc.

1 Automobile seat (vehicle seat)
2 Seat cushion 10 Cushion constituent member (constituent member)
11 Cushion pad (pad body)
12 Cushion cover (skin material)
12a Top plate main part (1st piece)
12a1 Main main part (first main part)
12a2 Main standing wall part (first standing wall part)
12a3 Corner part 12b Top plate side part (second piece)
12b1 Side main part (second main part)
12b2 Side standing wall part (second standing wall part)
12b3 Corner portion 12A Surface layer portion 12B Foam layer portion 12C Impregnated layer 20 Molding mold 21 Lower mold 21a Cavity surface 21a1 Main mold surface 21a2 Upright portion 22 Upper mold 22a Cavity surface 23 Cavity L1 Sewing line M Molding material

Claims (2)

A component of a vehicle seat in which a pad body serving as a cushioning material and a skin material covering the pad body are integrated during foam molding of the pad body,
The skin material is configured by laminating a surface layer portion disposed on the seating surface side and a foam layer portion having air permeability laminated on the opposite side of the surface layer portion to the seating surface,
The skin material is formed by integrating a plurality of pieces by sewing,
Adjacent first and second pieces among the plurality of pieces are connected by a sewing line,
The first piece has a first main part that forms a seating surface and a first vertical wall part that extends from the first main part in a direction away from the seating surface, and the second piece has a second main part that forms a seating surface. a main part and a second standing wall part extending from the second main part in a direction away from the seating surface; There is a sewing line,
A surface of the foam layer portion of the first main portion on the pad body side and a surface of the foam layer portion of the first vertical wall portion on the pad body side intersect at an acute angle without a gap;
A component of a vehicle seat, wherein a surface of the foam layer portion of the second main portion on the pad body side and a surface of the foam layer portion of the second vertical wall portion on the pad body side intersect at an obtuse angle. A mold for a component of a vehicle seat according to claim 1,
a lower mold in which the skin material is arranged so that the surface layer portion contacts a mold surface; and a pad body having a surface shape on the opposite side of the skin material of the pad body when closed with respect to the lower mold. an upper mold forming a cavity corresponding to the
A plate-shaped vertical plate part inserted between the first vertical wall part and the second vertical wall part is formed on the mold surface of the lower mold, and forms an acute angle with respect to the main mold surface that contacts the first main part. A mold for a component of a vehicle seat, which is arranged to intersect at an obtuse angle with respect to a main mold surface contacting the second main portion.

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