JP7460306B2 - Vehicle cushion pad and manufacturing method thereof - Google Patents

Description

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

The cushion pads that make up the seat of seats installed in vehicles such as automobiles have traditionally been made exclusively from soft polyurethane foam to provide comfortable cushioning. However, in recent years, with the aim of reducing weight, etc., inventions have been proposed in which the bottom layer of the cushion pad is made of a bead foam molded product made of polystyrene foam or polyolefin foam (for example, Patent Documents 1 to 3).

Patent No. 5277912 Japanese Patent Application Laid-Open No. 9-70330 Japanese Utility Model Application Publication No. 58-175756

Here, in Patent Documents 1 and 2, in which a core pad made of a bead foam molded body is present in the lower layer, the side surface is exposed and is not covered with a layer of soft polyurethane foam. There are problems with poor quality and feel. On the other hand, as in Patent Document 3, the polyolefin foam layer (the "core pad" in the present invention) is only exposed on the back side, and the side portions of the polyurethane foam layer (the "surface pad" in the present invention) are the core pad. If the side surface can be covered to the outer periphery of the back surface, the problems of poor cushioning properties and poor feel can be solved.
However, if the surface pad is configured to cover the side surface of the core pad up to the outer periphery of the back surface as in Patent Document 3, the foaming material will wrap around the back surface of the core pad and infiltrate toward the center of the back surface during foam molding of the surface pad. It was easy. The bead foam molded body of the core pad 2 has poor cushioning properties and sealing properties, and also tends to shrink due to its foam molding, making it more likely that the foaming raw material will infiltrate into the back surface 2b of the core pad (FIG. 11). The infiltrated foaming raw material forms a polyurethane film k on the back surface 2b of the core pad, which causes a problem of emitting a rubbing sound after the cushion pad 1 is mounted on a vehicle. Therefore, in a post-process after foam molding, a nonwoven fabric or the like must be attached to cover the soft polyurethane film k on the back surface 2b of the core pad in order to prevent rubbing noise, resulting in an increased labor burden.

The present invention aims to solve the above problems by providing a vehicle cushion pad and its manufacturing method that uses a core pad made of foamed bead molding, which helps reduce weight, exposes its back surface, and covers the sides of the core pad up to the outer periphery of the back surface with the sides of the surface pad, while preventing the foaming raw material from getting around to the back surface of the core pad during foam molding of the surface pad, thereby reducing the labor burden on workers and contributing to improved productivity.

In order to achieve the above object , the gist of the invention is to provide a method for manufacturing a cushion pad for a vehicle in which at least the receiving surface portion on the side that an occupant comes into contact with is formed of a surface pad of a soft polyurethane foam molded product, comprising: a bead foam molded product; , a thin plate portion is formed standing up at a low portion on the outer peripheral edge side of the back surface with a gap interposed between the wall surface on the outer peripheral edge side of the back surface extending from a low portion on the outer peripheral edge side to a raised high portion near the outer peripheral edge of the back surface. The core pad is used as an insert product, and a depression is provided in the upper mold in which it is set at a corresponding part of the high part including the thin plate part, and the depression is directed from the entrance toward the bottom surface toward the center of the depression. The thin plate part is provided with a side wall of an approaching inclined surface, so that the thin plate part slides on the inclined surface, and the vertical surface of the thin plate part on the outer peripheral edge side of the back surface is pressed against the side wall, and the thin plate part is placed in the recess together with the high part. The core pad is set in the upper mold by inserting the core pad into the upper mold, and then the soft polyurethane foaming raw material is injected into the lower mold cavity surface and the mold is closed.Then, the side portions of the core pad are covered to the outer peripheral edge of the back surface. A method for manufacturing a cushion pad for a vehicle, characterized by foam-molding a surface layer pad that is embedded and integrated. Further, in the method for manufacturing a cushion pad for a vehicle according to the invention , the thickness of the thin plate portion decreases from the base end portion connected to the low portion toward the tip portion, and the vertical surface increases toward the tip portion at the height. It is characterized in that it is tilted toward the wall surface in certain places. Further, in the method for manufacturing a vehicle cushion pad according to the invention , both the wall surface and the vertical surface of the thin plate portion are provided along the outer periphery of the back surface of the core pad, and the vertical surface is larger than the wall surface on the outer periphery of the back surface. It is characterized by a longer length along the periphery. Further, in the method for manufacturing a vehicle cushion pad according to the invention , the thin plate portion is separated from the high part by the gap running in the vehicle width direction, and is provided along the outer periphery of the rear surface of the vehicle in the vehicle width direction. Features.
Further, the gist of the invention is to provide a cushion pad for a vehicle in which at least the receiving surface portion on the side that an occupant comes into contact with is formed of a surface pad of a soft polyurethane foam molded product, which is made of a bead foam molded product, A core pad in which a thin plate portion having a surface facing the wall surface is formed upright on the outer peripheral edge side of the back surface with a gap between the wall surface on the outer peripheral edge side of the back surface extending from the low place part to the high place part that is raised one step, and the core. This cushion pad for a vehicle is characterized in that the pad is an insert product whose back surface is exposed, and a surface layer pad is buried and integrated with the side part of the core pad so as to cover the side surface of the core pad up to the outer periphery of the back surface. Further, in the vehicle cushion pad according to the invention , the thickness of the thin plate portion decreases from the base end portion connected to the low place portion toward the distal end portion, and the vertical surface decreases toward the top portion toward the high place portion. It is characterized by being inclined toward the wall surface side. Further, in the vehicle cushion pad according to the invention , both the wall surface and the vertical surface of the thin plate portion are provided along the outer periphery of the back surface of the core pad, and the vertical surface is provided along the outer periphery of the back surface more than the wall surface. It is characterized by a long length.

The vehicle cushion pad and the manufacturing method thereof of the present invention include a cushion pad in which a core pad of a bead foam molded product is embedded and integrated with a surface layer pad, which prevents foaming raw materials from entering the back surface of the core pad during molding of the surface layer pad, It does not require post-processing such as pasting tape, and is highly effective in reducing labor and improving productivity.

FIG. 2 is a perspective view of the cushion pad seen from the back side in one embodiment of the cushion pad and the manufacturing method thereof of the present invention. FIG. 2 is a perspective view of the cushion pad of FIG. 1 as viewed from the front surface side. A cross-sectional view showing a core pad set in an upper mold when the mold is open. This is a partially enlarged view just before the core pad is set in the upper mold. FIG. 5 is a partially enlarged view showing the state of FIG. 4 after the core pad has been set in the upper mold; FIG. 3 is a cross-sectional view of the foaming raw material being injected into the lower mold with the mold open. FIG. 7 is a sectional view of the mold closed from the state of FIG. 6; FIG. 2 is a cross-sectional view of a core pad and a surface pad integrated with the foam molding. FIG. 2 is a perspective view of a cushion pad according to another embodiment of the present invention, which is an alternative to that shown in FIG. 1 . FIG. 2 is a perspective view of another embodiment of the cushion pad in place of FIG. 1; FIG. 2 is an explanatory perspective view of a conventional cushion pad.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A vehicle cushion pad (hereinafter, simply referred to as a "cushion pad") according to the present invention and a method for manufacturing the same will be described in detail below.
(1) Manufacturing method of cushion pad Figures 1 to 10 show one embodiment of the cushion pad and its manufacturing method of the present invention, which are applied to a cushion pad for a rear seat of a vehicle. Figure 1 is a perspective view of the cushion pad seen from the back side, and Figure 2 is a perspective view of the cushion pad seen from the front side. Figure 3 is a cross-sectional view of the core pad set in the upper mold in the mold open state, Figure 4 is a partial enlarged view immediately before the core pad is set in the upper mold, Figure 5 is a partial enlarged view of the core pad set in the upper mold from the state of Figure 4, Figure 6 is a cross-sectional view of the foaming raw material being injected into the lower mold in the mold open state, Figure 7 is a cross-sectional view of the mold closed from the state of Figure 6, Figure 8 is a cross-sectional view of the surface pad integrated with the core pad foam-molded, and Figures 9 and 10 are perspective views of a cushion pad of another embodiment replacing Figure 1. In Figure 1, which shows the back side of the cushion pad, the upper left of the paper is the front of the vehicle of the cushion pad, and Figure 2 shows the cushion pad in a state of being installed in a vehicle, with the upper right of the paper being the front of the vehicle. In each drawing, in order to make the drawings easier to understand, the essential parts of the invention are emphasized, and parts that are not directly related to the present invention are simplified or omitted.

(1) Manufacturing method of vehicle cushion pad The manufacturing method of the vehicle cushion pad is a manufacturing method in which at least the receiving surface portion 31 on the side where the occupant comes into contact is formed from a soft polyurethane foam molded body, and the surface pad 3 of the soft polyurethane foam molded body is foam molded to bond the inner surface 3b side to a lightweight core pad 2 (Fig. 8). The side of the cushion pad 1 where the occupant comes into contact is the design surface. Here, this is applied to a cushion pad 1 for a three-seater seat in the rear seat of a vehicle as shown in Fig. 2. Prior to foam molding of the surface pad 3, the core pad 2 and a foam molding mold 7 are prepared.

The core pad 2 is a bead foam molded body, and is a core member having a high part 25 which is raised from a low part 24 on the outer peripheral edge side toward the center of the back surface near the outer peripheral edge 21 of the back surface 2b. Then, a slice having an opposing surface of a size matching the wall surface 251 is provided at a low portion 24 on the back surface outer peripheral edge 21 side with a gap ε interposed from the wall surface 251 on the back surface outer peripheral edge 21 side leading to the high portion 25. A thin plate portion 26 having a shape is formed in an upright manner. The thin plate part 26 is formed integrally with the core pad 2 by foam molding, and its thickness decreases from the plate thickness t1 to the plate thickness t2 from the base end part connected to the low part 24 toward the distal end part. In the present invention, a side that is relatively low relative to the high part 25 is referred to as a low part 24, and here, thin plate parts 26 are provided at three locations in the low part 24 on the outer peripheral edge 21 side beside the high part 25. (Figure 1).
On the rear surface 2b side of the core pad 2, a slightly elevated raised portion 28 is formed on the rear surface side of the seat portion of the main portion 3A in accordance with the three-seater seat portion, and each of the raised portions 28 is located on the outer side in the vehicle width direction with respect to the vehicle traveling direction. A thin plate portion 26 is provided at. In addition, a low part 24 is provided at the center of the rear side of the vehicle from the outer peripheral edge 21 of the back surface toward the front side of the vehicle, and from the low part 24, a step wall 271 is climbed up to become a step part 27 which is one step higher. The center of the vehicle in the width direction protrudes toward the rear of the vehicle. The protruding step part 27 is made into a high place part 25, and a gap ε is interposed between the wall surface 251 on the back side outer peripheral edge 21 side, and the low place surface 24a related to the low place part 24 on the back side outer peripheral edge 21 side is A thin plate portion 26 is provided at.
The core pad 2 of this embodiment is a bead foamed molded product of expanded polypropylene (EPP), and its apparent density is smaller than the apparent density of the surface layer pad 3 made of a flexible polyurethane foamed molded product. Reference numeral 22 indicates a plurality of locking grooves at the end of the skin, which are provided at predetermined intervals along the outer circumferential edge 21 of the back surface.

Here, the "back side" of the back side 2b of the core pad in the present invention is the "bottom side" of the paper, the surface on the lower side, and the surface on the vehicle floor side, in the case of the cushion pad 1 in FIG. 2 in a state of being attached to the vehicle. Also, the "bead foam molding" refers to a foam molding obtained by the so-called bead foaming method, which is a block-shaped foam molding formed by pre-foaming the raw material beads and then foaming in a mold. The bead foaming method is also simply called the bead method. The bead foam molding is preferably a molding containing polystyrene foam, polypropylene foam, polyethylene foam, or at least one of these. It is a bead foam molding with air bubbles sealed inside, and most of the volume is gas, making it lightweight, airtight, and shape-retaining, which is suitable for the core pad 2 that needs to maintain a moderate shape. By increasing the foaming ratio, the apparent density can be easily made smaller than that of a soft polyurethane foam molding.

The foaming mold 7 is a split mold as shown in FIG. 6, and a lower mold 8 and an upper mold 9 are connected to each other so as to be openable and closable. When the mold is closed as shown in FIG. 7, the entire mold is recessed into a bowl shape, forming a receiving surface 31 that becomes the designed surface 3a, and an upper mold cavity surface 91 that is aligned with the back surface 2b of the core pad 2. , create the cavity C of the cushion pad 1. The upper die 9 is provided with a set of core pads 2, and a recess 93 is provided at a corresponding portion of the high portion 25 including the thin plate portion 26.
In terms of the cavity surface 91 of the upper mold 9 corresponding to the VIII-VIII line arrow view in FIG. 1, when the core pad 2 is set in the upper mold 9 as shown in FIGS. The surface 911 passes through the side wall 931 of the recess 93 and reaches the bottom surface 935 of the recess 93 with which the high portion 25 comes into contact. The bottom surface 935 of the recess 93 in FIG. 4 that appears in the VIII--VIII arrow view extends directly to the right in the paper of the figure as the upper mold cavity surface 91. The side wall 931 is formed as an inclined surface approaching the center of the recess 93 from the entrance 930 of the recess 93 toward the bottom surface 935, and when the core pad 2 is set on the upper mold 9, the side wall 931 is formed on the back outer peripheral edge 21 side of the thin plate portion 26. The vertical surface 261 of is pressed against the inclined surface to facilitate sealing. The main side wall 931 shown in FIGS. 3 to 8 is a sloped surface extending from the entrance 930 of the vehicle rear side recess 93 to the bottom surface 935 of the recess 93 which becomes deeper on the vehicle front side. When the core pad 2 is set on the upper mold 9, the thin plate portion 26 in FIG. It is configured so that the side elevation 261 is pressed against it.
Reference numeral 912 is a cavity surface forming the side back surface 323 of the surface pad 3, and after the core pad 2 is set in the upper mold 9, it is located outside the outer peripheral edge 21 of the back surface of the core pad 2 when the mold is closed. Reference numeral 86 indicates a raised portion for a hanging groove, and reference numerals 89 and 99 indicate a mold matching surface.
The foam molding mold 7 shown in FIGS. 3 to 6 is a mold for making a surface pad 3 integral with the core pad 2, which is the cushion pad, in an upside-down position with respect to the cushion pad 1 shown in FIG. 2 installed in the vehicle. It has a structure.

Using the foaming mold 7 and core pad 2, the cushion pad 1 is manufactured, for example, as follows.
First, prior to manufacturing, the groove opening of the locking groove 22 is closed with tape, and the core pad 2 is set in the upper mold 9 while the foaming mold 7 is in an open state (FIG. 3). When the core pad 2 is attached and set on the upper die 9, the tip portion 26a of the thin plate portion 26 first hits the side wall 931 formed on the slope of the recess 93 (FIG. 4). In this state, the core pad 2 is pressed upward where the upper die 9 is located. Then, the thin plate portion 26 slides on the sloped surface of the side wall 931 and is deformed by nestling against the sloped surface, and fits into the recess 93 together with the high portion 25 to set the core pad 2 on the upper mold 9. is completed (Figures 5 and 6). As shown in FIG. 4, the vertical surface 261 of the thin plate portion 26 is inclined toward the wall surface 251 of the high portion 25 toward the tip portion 26a, so that it is easily deformed by nestling against the slope surface of the side wall 931. . At least a portion of the vertical surface 261 of the thin plate portion 26 is in close contact with the side wall 931 in a pressed and deformed state as shown in FIG. Even if the core pad 2 is made of a bead foam molded product, it has the deformable flexibility shown in FIG. 4 by forming the thin plate part 26 in a slice shape, and furthermore, the thin plate part 26 has a shape that extends from the proximal end to the distal end. By reducing the thickness toward the end, the thin plate portion 26 can smoothly accommodate the deformation shown in FIG.
3 to 6 show how the thin plate portion 26 provided at the center of the rear side of the vehicle and the high portion 25 are set into the recess 93 through a gap ε as shown in the VIII-VIII line arrow view in FIG. 1. However, the same applies to the thin plate portions 26 formed on the left and right outer sides of the raised portion 28 in the vehicle width direction with respect to the vehicle traveling direction. The thin plate portions 26 located on the left and right outer sides of the raised portion 28 in the vehicle width direction are also deformed into an arched shape by sliding on the inclined surface of the side wall 931, and the vertical surface 261 on the back outer peripheral edge 21 side is transformed into an inclined side wall of the recess 93 (not shown). 931, the thin plate part 26 and the high part 25 provided at the center of the rear side of the vehicle are inserted into the recess 93 together with the thin plate part 26 and the high part 25, and the core pad 2 is inserted into the upper mold. Set to 9.

Next, a soft polyurethane foaming raw material g (hereinafter simply referred to as "foaming raw material") for molding the surface pad 3 is injected into the lower mold cavity surface 81, and the mold is closed.
A predetermined amount of foaming raw material g is injected onto the bowl-shaped lower mold cavity surface 81 using an injection nozzle NL or the like (FIG. 6). Next, the upper mold 9 is operated and the mold is closed (FIG. 7). By closing the upper mold 9 and the lower mold 8, a cavity C for the cushion pad 1 in which the core pad 2 is inserted is formed. When the mold is closed, the hanging groove raised portion 86 may be brought into contact with the surface 2a of the core pad 2 to support the core pad 2 from below and hold it within the cavity C. Note that after setting the core pad 2 in the upper mold 9, the foaming raw material g was injected, and then the mold was closed. It can also be injected.

After closing the mold, the main process of foam molding of the surface layer pad 3 is started. The mold closed state shown in FIG. 7 is maintained for a predetermined period of time, and the surface pad 3 is made of a soft polyurethane foam molded body with the core pad 2 embedded and integrated therein, having a receiving surface portion 31 on the side of the design surface 3a that the seated occupant contacts. Foam molding.
In the initial stage of foam molding, foaming of the foaming raw material g progresses. After filling the cavity C of the receiving surface portion 31, the foaming raw material g rises and reaches the upper mold cavity surface 91. While the foaming raw material g is rising, the foaming raw material g tries to wrap around and enter the back surface 2b of the core pad, but as described above, the vertical surface 261 of the thin plate portion 26 is pressed against the side wall 931 of the recess 93 to seal it. Therefore, the progress of the foaming raw material g stops there. With the foaming raw material g blocked from entering the back surface 2b of the core pad beyond the thin plate portion 26, the surface pad 3 is foam-molded to fill up to the back surface 323 of the side portion 32 as shown in FIG. A surface layer pad 3 in which a core pad 2 is embedded and integrated is foam-molded.
The core pad 2 may sometimes shrink during product manufacturing, but even if it shrinks, the side wall 931 that the tip portion 26a of the thin plate portion 26 touches becomes an inclined surface when the core pad 2 is set on the upper mold 9. Therefore, in FIG. 4, even if the core pad 2 contracts in the lateral direction in the plane of the paper, there is a permissible range of the inclined side wall 931 that accommodates the tip end portion 26a of the thin plate portion. Therefore, even if there is some deviation in dimension due to shrinkage of the core pad 2, the vertical surface 261 of the thin plate portion 26 can be pressed against the side wall 931 without difficulty, and the thin plate portion 26 can be deformed and brought into close contact with the side wall 931 for sealing. . The pressing of the thin plate portion 26 against the side wall 931 may be supported by the support of the hanging groove raised portion 86 described above.

The mold closed state shown in FIG. 7 is maintained for a predetermined period of time, the back surface 2b of the core pad 2 is exposed, and the side portion 32 covers the side surface 23 of the core pad 2 from the core pad surface 2a side to the outer peripheral edge 21 of the back surface, and the core pad A surface layer pad 3 in which pads 2 and 2 are embedded and integrated is foam-molded.
When the foam molding is completed and the mold is removed, the receiving surface portion 31 is formed, and since the thin plate portion 26 blocks the foaming raw material g from entering the center side of the back surface 2b of the core pad during foam molding, the foaming raw material g is deposited there. To obtain a desired cushion pad 1 free of burrs. The tape that blocked the locking groove 22 is removed after demolding.

In this embodiment, the entire circumferential surface of the core pad side surface 23 is covered with the side portion 32 as shown in FIG. 2, but portions that are not particularly touched by the occupant may be omitted. Further, as shown in FIGS. 1 to 8, the size of the wall surface 251 on the back outer peripheral edge 21 side of the high part 25 and the size of the opposing surface of the thin plate portion 26 facing the wall surface are made approximately the same size. For example, as shown in FIG. 9, the vertical surface 261 of the thin plate portion 26 can be made larger than the wall surface 251. In the high part 25 and the thin plate part 26 disposed at the center on the rear side of the vehicle in FIG. Although it is provided along the outer peripheral edge 21, the length of the vertical surface 261 along the back outer peripheral edge 21 is set longer than that of the wall surface 251. A length L6 of the vertical surface 261 in the vehicle width direction is longer than a length L5 of the wall surface 251 in the vehicle width direction. This thin plate part 26 widens the protection area in the vehicle width direction that blocks the foaming raw material g from entering from the core pad back surface outer peripheral edge 21 on the vehicle rear side to the center side of the core pad back surface 2b, which is more preferable.
In addition, a locking groove 22 is provided in a high place 25 on the rear side of the vehicle, and a thin plate part 26 having a length in the vehicle width direction is formed upright in a low place 24 to cover the locking groove as shown in FIG. 10. A core pad 2 can also be used. In the foam molding of the surface pad 3 in which the core pad 2 is embedded and integrated, the thin plate portion 26 not only prevents the foaming raw material g from penetrating into the back surface 2b of the core pad, but also prevents the foaming raw material g from penetrating into the locking groove 22. Therefore, it is not necessary to close the groove opening of the locking groove 22 covered by the thin plate portion 26 with tape prior to foam molding. Although the drawing in which the core pad 2 is set on the upper die 9 is omitted, in FIG. 5, the locking groove 22 is formed with a groove opening in the high-place top surface 25a near the wall surface 251. In FIG. 10, the thin plate portion 26 is slid on the inclined surface of the side wall 931, and the vertical surface 26 on the back outer peripheral edge 21 side is
1 to the side wall 931, the thin plate portion 26 is divided into three parts, but it may be made into a single piece.
Note that the other configurations in FIGS. 9 and 10 are the same as those described above in FIGS. 1 to 8, and their explanation will be omitted. The same reference numerals as in FIGS. 1 to 8 indicate the same or corresponding parts. Reference numeral 3B indicates a side portion, reference numeral 3D indicates an inclined surface, reference numeral 3E indicates a joint portion with the backrest, and reference numerals 391 and 392 indicate vertical and horizontal grooves of the hanging groove 39.

1 to 8, the cushion pad 1 for a vehicle is configured such that the surface 2a side of the core pad 2 is covered with a surface layer pad 3 made of a soft polyurethane foam molded body. At least the receiving surface portion 31 on the side where an occupant comes into contact is formed of a soft polyurethane foam molded body, thereby forming the cushion pad 1 having the core pad 2 and the surface layer pad 3.

The core pad 2 is a block-shaped bead foam molded body that occupies almost the lower half of the cushion pad 1. The core member is formed with a slice-shaped thin plate portion 26 that has a facing surface of a size that matches the wall surface 251 on the back outer edge 21 side, with a gap ε, on the back outer edge 21 side, which extends from the low part 24 on the outer edge side to the high part 25 that is raised up one step near the outer edge 21 of the back surface 2b. Both the wall surface 251 in the high part 25 and the vertical surface 261 of the thin plate portion 26 are provided along the back outer edge 21 of the core pad 2. The plate thickness of the thin plate portion 26 decreases from the base end portion connected to the low part 24 toward the tip portion. Furthermore, the vertical surface 261 of the thin plate portion 26 located on the outer edge side toward the tip portion 26a is inclined toward the wall surface 251 of the high part 25. The skin end engagement grooves 22 are provided near the outer periphery 21 of the back surface as shown, and are arranged at predetermined intervals around the entire circumference of the outer periphery 21 of the back surface.

The surface pad 3 is a soft polyurethane foam molded body in which the core pad 2 is embedded and integrated with the back surface 2b of the core pad 2 exposed. A receiving surface portion 31 is formed on the design surface 3a side of the soft polyurethane foam molded body, while the inner surface 3b side opposite the design surface 3a is joined to the surface 2a of the core pad 2. The surface pad 3 embeds and integrates the core pad 2 as an insert product with its back surface 2b exposed, with the side portion 32 covering the side surface 23 of the core pad 2 from the front surface 2a side to the outer peripheral edge 21 of the back surface. The core pad 2 is wrapped in the surface pad 3 with its back surface 2b exposed, as shown in Figures 1 and 8.

The cushion pad 1 is provided with a thin plate portion 26 for preventing foaming raw material g from penetrating into the back surface 2b of the core pad during foam molding of the surface pad 3. In this embodiment, a slice-shaped thin plate portion 26 having an opposing surface of a size matching the wall surface 251 is formed upright on the back outer peripheral edge 21 side with a gap ε from the wall surface 251 of the high place portion 25. (Figures 1 to 8). By foam molding the surface pad 3, the desired cushion pad 1 is obtained in which the foaming raw material g is prevented from penetrating into the back surface 2b of the core pad.

Furthermore, FIG. 9 shows a cushion pad 1 of another embodiment, in which the vertical surface 261 of the thin plate portion 26 is longer along the outer peripheral edge 21 of the back surface than the wall surface 251 of the high portion 25. It is. Further, FIG. 10 shows that a locking groove 22 is provided in a high place 25 on the rear side of the vehicle, and a thin plate part 26 that is longer in the vehicle width direction and covers the locking groove 22 in the vehicle width direction is installed in a lower place. The core pad 2 is formed upright along the outer periphery 21 of the back surface of 24.
The other configurations are the same as those described in (1) Method for manufacturing a vehicle cushion pad, and the explanation will be omitted. The same reference numerals as those in (1) indicate the same or equivalent parts.

(3) Effect The vehicle cushion pad and its manufacturing method configured as described above have a core pad 2 made of a shape-retaining and extremely light bead foam molded product, and a surface layer pad 3 made of a soft polyurethane foam molded product embedded therein. Therefore, the weight of the cushion pad 1 can be reduced. However, since at least the receiving surface portion 31 on the side that the passenger comes into contact with is formed of the surface pad 3 made of a soft polyurethane foam molding, comfortable cushioning properties are maintained when the passenger is seated.

Although the core pad 2 made of a bead foam molded product is less likely to deform than the surface pad 3 having cushioning properties, it still has flexibility and can handle deformation by forming the thin plate portion 26. Assuming that the core pad 2 is formed in an upright manner with a thin plate portion 26 having a surface facing the wall surface 251 of the high portion 25 through a gap ε, a recess 93 is provided in the upper die 9 in which it is set, and an entrance is provided in the recess 93. By providing a side wall 931 with an inclined surface approaching the center of the recess 93 from 930 toward the bottom surface 935, the thin plate portion 26 can slide on the inclined surface, and the vertical surface 261 on the outer peripheral edge 21 side of the back surface can be connected to the side wall 931. The core pad 2 can be successfully set in the upper mold 9 by pressing it against the upper mold 9. Since the vertical surface 261 of the thin plate part 26 can be pressed against the side wall 931 for sealing, when the surface pad 3 is foam-molded, the foaming raw material g wraps around to the back surface 2b of the core pad and intrudes toward the center of the back surface at the site of the vertical surface 261. You can stop it with . In molding the surface pad 3, a polyurethane film k is formed on the back surface 2b of the core pad 2, and this solves the conventional problem of emitting a rubbing sound after the cushion pad 1 is mounted on a vehicle. In a post-process after foam molding, there is no need to attach a nonwoven fabric or the like to cover the soft polyurethane film k on the back surface 2b of the core pad to prevent rubbing noise.
The surface pad 3 is configured to cover the side surface 23 of the core pad 2 up to the outer peripheral edge 21 of the back surface, and the side surface 23 of the core pad 23 that is touched by the passenger is also covered with the side surface 32 of the surface pad 3, resulting in a cushion pad with good cushioning properties and feel. It is possible to set it to 1.

By the way, the bead foam molded body of the core pad 2 tends to shrink due to its foam molding, making it more likely that the foaming raw material g will infiltrate into the back surface 2b of the core pad. However, by making the upper mold 9 have a side wall 931 with an inclined surface where the recess 93 approaches the center side of the recess 93 from the entrance 930 toward the bottom surface 935, when the core pad 2 is set in the upper mold 9, the side wall of the inclined surface The area in which the thin plate part 26 can be pressed against the core pad 931 is expanded, and even if the core pad 2 has some dimensional shrinkage, the cushion pad can reliably prevent the foaming raw material g from penetrating into the back surface 2b of the core pad.
Furthermore, if the thickness of the thin plate portion 26 decreases from the proximal end portion connected to the low point portion 24 toward the distal end portion, the thin plate portion 26 will have further flexibility and be able to accommodate deformation. Therefore, it is more reliable to press the vertical surface 261 of the thin plate portion 26 against the side wall 931 for sealing.
In addition, if the vertical surface 261 is tilted toward the wall surface 251 of the high portion 25 toward the tip portion 26a of the thin plate portion 26, deformation can be handled more smoothly, and the thin plate portion 26 can move along the inclined surface of the side wall 931. The operation of pressing the vertical surface 261 on the side of the outer peripheral edge 21 of the back surface against the side wall 931 proceeds smoothly in a sliding manner. Setting the core pad 2 to the upper mold 9 becomes easier.

Furthermore, if the thin plate part 26 is separated from the high part 25 by a gap ε running in the vehicle width direction and is provided along the outer periphery in the vehicle width direction on the rear surface of the rear side of the vehicle, when the surface pad 3 is foam-molded, Since the thin plate portion 26 effectively blocks the foaming raw material g from entering the back surface 2b of the core pad from the side, the formation of a polyurethane film k by wrapping around the back surface 2b of the core pad from the rear side of the vehicle, which was easily caused in the past. can be eliminated.
Furthermore, as shown in FIG. 9, if the vertical surface 261 of the thin plate part 26 is set longer along the back outer peripheral edge 21 than the wall surface 251 of the high part 25, the foaming of the surface pad 3 Therefore, it is possible to prevent the foaming raw material g from going around to the high place part 25 over a wider range by using the long thin plate part 26.
In this way, even if the side portion 32 of the surface pad 3 covers the core pad side surface 23 from the front surface 2a side to the back outer peripheral edge 21, the foaming material g will not go around to the core pad back surface 2b during foam molding of the surface pad 3. . Therefore, there is no need to worry about the problem of rubbing noise after the cushion pad 1 is installed in a vehicle, and the work burden of pasting non-woven fabric or the like on the back surface 2b of the core pad to prevent the rubbing noise. It has excellent effects in stabilizing quality and improving productivity.

Note that the present invention is not limited to what is shown in the embodiments described above, and can be variously modified within the scope of the present invention depending on the purpose and use. The shape, size, number, material, etc. of the core pad 2, low portion 24, high portion 25, thin plate portion 26, surface pad 3, foam mold 7, depression 93, etc. can be selected as appropriate depending on the application.

REFERENCE SIGNS LIST 1 cushion pad 2 core pad 21 back surface outer periphery 23 side surface 24 low portion 25 high portion 251 wall surface 26 thin plate portion 26a vertical surface 3 surface pad 31 receiving surface portion 32 side portion 81 lower mold cavity surface 9 upper mold 93 recess 931 side wall g foaming material

Claims (5)

A method for manufacturing a vehicle cushion pad in which at least a receiving surface portion on a side where an occupant comes into contact is formed of a surface layer pad of a soft polyurethane foam molding, comprising:
A bead foam molded body, in which a core pad having a flexible thin plate portion formed along the outer periphery of the back surface near the outer periphery is used as an insert product, and an upper mold for setting this is provided with a recess in a corresponding portion of the thin plate portion into which the thin plate portion is fitted when the mold is closed, and the recess is provided with a side wall having an inclined surface approaching the center of the recess from the entrance toward the bottom surface,
A method for manufacturing a vehicle cushion pad, characterized in that the thin plate portion slides along the inclined surface, the vertical surface of the thin plate portion on the outer peripheral edge side of the back surface is pressed against the side wall, the thin plate portion is inserted into the recess and the core pad is set in the upper mold, soft polyurethane foaming raw material is then injected into the cavity surface of the lower mold and the mold is closed, and then a surface pad is foam-molded to cover the side surface of the core pad with the side portion up to the outer peripheral edge of the back surface and embedded and integrated. A vehicle cushion pad in which at least a receiving surface portion on the side where an occupant comes into contact is formed of a surface layer pad of a soft polyurethane foam molding,
A core pad that is a bead foam molded product and has a flexible thin plate portion standing up along the outer periphery of the back surface near the outer periphery of the back surface;
The vehicle cushion pad is characterized in that the core pad is an insert product with its back surface exposed, and the pad is provided with a surface layer pad which covers the side surface of the core pad up to the outer peripheral edge of the back surface at the side portion and is embedded and integrated therewith. 3. The vehicle cushion pad according to claim 2, wherein the thickness of said thin plate portion decreases from a base end portion connected to the back surface of said core pad toward a tip portion. A vehicle cushion pad as described in claim 2 or 3, wherein the thickness of the thin plate portion decreases from the base end portion connected to the back surface of the core pad toward the tip portion, and the vertical surface on the outer peripheral edge side of the back surface of the thin plate portion is inclined toward the inside of the back surface related to the core pad toward the tip portion. The thin plate portion has a facing surface and is formed upright with a gap interposed against a wall surface of a high place that is raised toward the center of the back surface of the core pad, and further has a top surface of the high place. The cushion pad for a vehicle according to any one of claims 2 to 4, wherein a locking groove having a groove opening on the surface is provided closer to the wall surface.

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