JPH10156073A - Manufacture of vehicle seat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable mass production of vehicle seat having solidity by forming parting sections through ridge sections by applying suction force on a drag, where a top plate surface of the outer layer material is set, then reversing a molded cushion body and uniting the molded cushion body to the back side of the top plate by pressurizing through a cope. SOLUTION: When a molded cushion body 11 is adhered to the back side of a top plate 2, a molded surface, molded on the surface of the top plate 2 of the bag-shaped outer layer material made of seamless ground, is set on the tops of the ridge sections 22 formed on a drag 21. Then, the suction force is applied to the molded surface of the drag 21 through small holes 23. Thereby, the top plate 2 is adhered and held to the molded surface of the drag 21, and parting sections 4 are formed on the top plate 2 through the ridge sections 22. Then the molded cushion body 11 is reversed and the parting sections 4 and deep grooves 12 are fitted and placed. The molded surface is butted to the back side of the molded cushion body 11 to be pressed through a cope, and the molded cushion body 11 is adhered and united to the back side of the top plate 2 using a hotmelt adhesive.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an inexpensively mass-produced vehicle seat in which a molded cushion body is integrally bonded to a top plate portion of a bag-like skin material, which is integrally bonded. Things.

[0002]

2. Description of the Related Art In a vehicle seat such as an automobile seat, a main body in which a molded cushion body is integrally bonded to a top plate portion of a bag-shaped skin material is mainly used. Then, the bag-shaped skin material is set in the lower mold, the top plate surface of the skin material is set as the mold surface side, and the molded cushion body is placed in an inverted shape, and this is pressed by the upper mold to press the top plate of the skin material. It is normal to integrate a molded cushion body on the back of the part with an adhesive that is interposed between them, but the conventional one consisting of one piece of cloth for the top plate of the skin material has changed in the pattern of the cloth It is difficult to make it excellent in design and poor,
In recent years, it has become popular to stitch a plurality of different kinds of fabrics to give a change to the pattern so that a deep groove is formed in the top plate portion or the pattern is changed. However, in order to form a deep groove on the top plate or to sew a plurality of different kinds of fabrics, it is inevitable that sewing work and drawing work for forming the deep groove are troublesome and costly. there were.

[0003]

The object of the present invention is to solve the above-mentioned conventional problems and to provide a vehicle seat having a three-dimensional appearance on a seat top plate and excellent design. It is an object of the present invention to provide a method of manufacturing a vehicle seat which can be mass-produced with a great deal of trouble at low cost.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems.
A bag-shaped skin material having a top plate portion as a seamless fabric is converted into a lower mold having a vacuum forming function in which a ridge portion for forming a parting portion is formed on a mold surface, and the surface of the top plate portion of the skin material is formed. After being set as the mold surface side, a suction pressure is applied to the lower mold to cause the top plate portion to be sucked and held on the lower mold surface, and a parting portion is formed by a ridge portion, and then the above-described portion is formed thereon. Place the molded cushion body with the deep groove corresponding to the ridge of the lower mold on the surface in reverse, and press it with the upper mold to interpose the molded cushion body on the back of the top plate of the skin material The present invention is characterized in that the adhesive is integrated with the adhesive.

[0005] In the above invention, the seamless fabric forming the top plate portion of the bag-shaped skin material has a design pattern formed on the surface thereof with a portion corresponding to the parting-off portion as a boundary. By setting the border of the design pattern to the ridge for forming the parting part of the lower mold and setting the bag-shaped skin material to the lower mold, a plurality of different kinds of fabrics are sewn to change at the seam. The invention according to claim 2 is intended to exhibit the same design effect as that provided, and in these inventions, the top plate portion of the bag-shaped skin material is attached to the back surface of the seamless fabric. The wadding material shall be composed of laminated dough, and before this laminating dough is set in the lower mold as a bag-like skin material, by embossing the part corresponding to the parting portion with a tooth mold, Alignment when setting the skin material to the lower mold What made the work easy is the invention according to claim 3, and in each of the above-mentioned inventions, an adhesive interposed between the top plate portion of the skin material and the molded cushion body is used. 5. A method according to claim 4, wherein the hot melt adhesive is preliminarily coated on one of the bodies, and the adhesive is imparted to the hot melt adhesive by heating with a hot fluid supplied from a lower mold. The invention.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail with reference to the drawings. Reference numeral 1 denotes a bag-shaped skin material in which a gore portion 3 made of an arbitrary material is sewn to a top plate portion 2 made of a seamless fabric, and a double-row heterogeneous pattern extending in the front-rear direction is provided on the surface of the top plate portion 2. 5a, 5b, 5c are formed, and at the boundary between the different patterns 5a, 5b, 5c, a parting portion 4 having a V-shaped cross section to be described later is formed on the top plate portion 2, Positioning points are formed at both ends of each parting portion 4 to facilitate alignment with a set reference pin. In addition, the above-mentioned heterogeneous belt pattern 5a,
What means 5b and 5c are different kinds of patterns that have a change in design, such as different colors due to different fibers or prints, different patterns, different feels due to flocking, etc. May be different. Further, the top plate portion 2 may be made of a seamless fabric, but may be made of a laminated fabric in which a wadding material 2b is laminated on the back surface of a surface material 2a as shown in the drawing.
In this case, as shown in FIG. 6, a portion corresponding to the above-mentioned parting portion 4 of the laminated fabric is subjected to embossing 6 by a tooth mold before being set in the lower mold as the bag-shaped skin material 1. It is preferable to keep The top plate portion 2 made of the seamless fabric as described above can be easily obtained by simply cutting the rolled fabric as shown in FIG. 5 to a required size using a cutting die (not shown). it can.

On the other hand, reference numeral 11 denotes a molded cushion body integrated with the back surface of the top plate 2 of the bag-shaped skin material 1, and the molded cushion body 11 is a well-known foam made of polyurethane resin or the like. Although a detailed description is omitted since it is obtained by a molding method, a deep groove 12 corresponding to a ridge portion 22 of a lower mold 21 described later is formed on the surface thereof, and the back surface of the molded cushion body 11 is formed. Reference numeral 13 is formed to have a shape that can be fitted to the frame. Note that a hot melt adhesive should be applied in advance to the front surface of the molded cushion body 11 or the rearmost surface of the top plate 2 of the skin material 1, that is, the back surface of the wadding material 2 b when the material is a laminated skin material. Is preferred.

Reference numeral 21 denotes a lower mold having a vacuum forming function in which a ridge 22 for forming a parting part having a mountain-shaped cross section is formed on the mold surface. Micropores 23 are also provided for blowing out the fluid, and 24 is an upper mold that can freely contact and separate from the lower mold 21, and the forming mold composed of the lower mold 21 and the upper mold 24 is also raised. Except for the fact that the ridges 22 are formed, there is almost no difference from the molding die used in the conventional method of manufacturing a vehicle seat of this type, and a detailed description thereof will be omitted.

Next, the top plate portion 2 of the bag-shaped skin material 1 described above.
The step of bonding the molded cushion body 11 to the back surface of the above-described member using the lower mold 21 and the upper mold 24 will be described. First, a bag-shaped skin material 1 in which a top plate portion 2 is made of a seamless fabric is placed on a lower mold 21 having a vacuum forming function in which a ridge portion 22 for forming a parting portion is formed on a mold surface. The surface of the top plate portion 2 is set as the mold surface side, and the portion of the embossing 6 by the above-mentioned tooth mold is set at the top of the ridge portion 22 and then set.
When a suction pressure is applied to the mold surface of the first mold 1 through the fine holes 23, the top plate 2 is adsorbed and held on the mold surface of the lower mold 21 as shown in FIG. The parting portion 4 having a V-shaped cross section is formed on the top plate portion 2 of the skin material 1 by the formed ridge portion 22.

In this way, the bag-shaped skin material 1 is
After being set on the mold surface and being held by suction on the mold surface, as shown in FIG. 2, a molded cushion body 11 on which a deep groove 12 corresponding to the ridge portion 22 of the lower mold 21 is formed. Is turned upside down, and the V-shaped parting portion 4 and the deep groove 12 are placed in alignment with each other.
The upper mold 24 is lowered after the mold surface is brought into contact with the back surface 13 of the lower body 13, and as shown in FIG. 3, the lower cushion 21 and the upper mold 24 separate the molded cushion body 11 and the top plate 2 of the skin material 1. Pressing,
In this state, when the suction pressure on the mold surface of the lower mold 21 is released and a heat fluid such as high-pressure steam is supplied to the mold surface through the fine holes 23, the heat fluid flows through the top plate 2 of the skin material 1. Since the hot-melt adhesive having the molded cushion body interposed therebetween on the back surface of the top plate portion is heated to provide an adhesive property, the molded cushion body 11 is formed by the hot-melt adhesive.
After that, the hot fluid supplied to the mold surface through the pores 23 is switched to cold air to cool and solidify the hot melt adhesive, and then the upper mold 24 is removed. Raise and remove the mold. If the gore portion 3 is turned over and the periphery of the molded cushion body 11 is covered by the gore portion 3, a product as shown in FIG. 4 is obtained. The product is formed into a frame like a conventional vehicle seat of this type. It can be mounted and used.

[0011] The vehicle seat thus obtained is:
Despite the fact that the top plate 2 of the skin material 1 is made of one piece of cloth, a double-row heterogeneous pattern 5 extending in the front-rear direction on the surface of the top plate 2
a, 5b and 5c are formed, and
Since the boundary portions of a, 5b, and 5c are cut into the deep groove 12 of the molded cushion body 11 as a parting portion 4 having a V-shaped cross section and are adhered, a plurality of different kinds of fabrics are sewn to change at the seam. It has the same three-dimensional effect as the vehicle seat manufactured by the conventional complicated manufacturing process in which the sewn portions are deeply drawn, and also has excellent color tone and excellent design. In addition, the manufacturing process does not require the need to sew a plurality of different kinds of fabrics, and the work of pulling in and assembling to the frame can be greatly simplified, so that it can be provided at low cost.

[0012]

As is apparent from the above description, the present invention provides a method for manufacturing a vehicle seat which can be mass-produced in a simple and inexpensive manner using a design-excellent vehicle seat having a three-dimensional appearance on a seat top plate. There is something extremely large that contributes to the development of the industry.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a state in which a skin material is sucked into a lower mold in the method of the present invention.

FIG. 2 is a cross-sectional view showing a state in which a molded cushion body is placed on a lower mold to which a skin material is sucked in the method of the present invention.

FIG. 3 is a cross-sectional view showing a step of bonding a molded cushion body to a skin material by pressing with an upper die in the method of the present invention.

FIG. 4 is a partially cutaway front view showing an example of a vehicle seat obtained by the method of the present invention.

FIG. 5 is a perspective view of a rolled dough, which is a material of a top plate portion of a skin material used in the method of the present invention.

FIG. 6 is a sectional view showing an example of a top plate portion of a skin material used in the method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Bag-shaped skin material 2 Top plate part 4 Parting part which makes section V-shaped 11 Molded cushion body 12 Deep groove 21 Lower mold 22 Ridge part of mountain cross section 23 Pores 24 Upper mold

Claims (4)

[Claims] 1. A bag-shaped skin material having a top plate portion as a seamless fabric is converted into a lower mold having a vacuum forming function in which a ridge for forming a parting portion is formed on a mold surface. After setting the top plate surface as the mold surface side, apply suction pressure to the lower mold to cause the top plate to be sucked and held on the lower mold surface, and form a parting part by the ridges, A molded cushion body having a deep groove corresponding to the ridge portion of the lower mold is formed on the surface thereof, and the molded cushion body is placed upside down. The molded cushion body is pressed by the upper mold and formed on the back surface of the top plate portion of the skin material. The method for manufacturing a vehicle seat according to claim 1, wherein the first and second adhesives are integrated into an adhesive interposed therebetween. 2. A seamless fabric forming a top plate portion of a bag-shaped skin material, wherein a design pattern having a boundary corresponding to a parting portion is formed on a surface thereof, and a boundary portion of the design pattern is formed. 2. The method for manufacturing a vehicle seat according to claim 1, wherein the bag-shaped skin material is set in the lower mold by matching the ridge with a ridge for forming a parting part of the lower mold. 3. The top plate portion of the bag-shaped skin material is made of a laminated fabric in which a wadding material is laminated on the back surface of a seamless fabric, and the laminated fabric has a lower mold as a bag-shaped skin material. 3. The method for manufacturing a vehicle seat according to claim 1, wherein a part corresponding to the parting portion is embossed by a tooth mold before setting. 4. An adhesive to be interposed between the top plate portion of the skin material and the molded cushion body is a hot melt adhesive previously layered on one of the top plate portion and the molded cushion body. The hot melt adhesive is provided with an adhesive ability by heating with the supplied hot fluid.
4. A method for manufacturing a vehicle seat according to item 2 or 3.