JP2019025201A - Manufacturing method of seat cushion material, and foaming mold for manufacturing the same - Google Patents

Abstract

To provide a manufacturing method capable of manufacturing by suppressing an increase in man hours, a seat cushion material in which a front layer pad and a back layer pad arranged at an opposite side of a seating face of the front layer pad and having a density smaller than that of the front layer pad are integrated, and to provide a foaming mold for manufacturing the same.SOLUTION: A manufacturing method of a cushion pad in which a front layer pad 10 and a back layer pad 20 harder and having a smaller density than the front layer pad 10 are integrated includes: a preparation step of fixing the back layer pad 20 to an upper cavity surface 42a by bringing a peripheral edge part 22a of a back side part 22 into contact with a tube-like member 50; a molding step of molding the front layer pad 10 by charging a foam urethane resin material M onto a lower cavity surface 41a of a lower mold 41 in which a rear projection 41a1 and a front projection 41a2 for pushing the back layer pad 20 to the upper cavity surface 42a when closing an upper mold 42 are arranged on a lower cavity surface 41a, and closing the upper mold 42; and a mold removing step of removing the molded cushion pad from the mold.SELECTED DRAWING: Figure 12

Description

  The present invention relates to a method for manufacturing a seat cushion material constituting a vehicle seat and a foaming mold for manufacturing the seat cushion material.

  Conventionally, a two-layer pad body is known as a cushioning material for a vehicle seat. In the following Patent Document 1, the surface layer pad on the seating surface side is polyurethane foam obtained by foaming polyurethane resin, and the back layer pad disposed on the opposite side of the seating surface of the surface layer pad is AS resin (acrylonitrile / styrene copolymer). A pad body having a two-layer structure, which is a foam obtained by foam molding, is disclosed. Usually, when manufacturing this pad body, it has a lower mold and an upper mold, and when the upper mold is closed with respect 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 type. The cavity surface of the lower mold is formed in a shape corresponding to the shape of the surface side (sitting surface side) of the pad body, and the cavity surface of the upper mold is the shape of the back surface side (opposite side of the seating surface) of the pad body. It is formed in the shape corresponding to. The state where the back surface of the back layer pad is mechanically fitted to the cavity surface of the upper mold or temporarily held by the magnetic force acting between the magnet embedded in the cavity surface of the upper mold and the iron member inserted into the back layer pad. Thus, the foam body is injected into the cavity surface of the lower mold, the upper mold is closed with respect to the lower mold, and the pad body is manufactured.

JP 2010-125138 A

  In the method for manufacturing a pad body having a two-layer structure described in Patent Document 1, from the edge of the peripheral edge of the back surface of the back layer pad that comes into contact with the cavity surface of the upper mold in the process in which the foamed polyurethane resin material is foam-cured. There was a problem that a part of the foamed polyurethane resin raw material entered between the cavity surface of the upper mold and the back surface of the back layer pad, and foamed and cured. If a part of the foamed polyurethane resin material penetrates between the cavity surface of the upper mold and the back surface of the back layer pad and foams and hardens, the pad body mounting surface of the vehicle body and the back surface of the back layer pad do not adhere to each other. The height deviates from the design value. In order to avoid this, there is a problem that the number of work steps increases when the foam formed on the back surface of the back layer pad is to be removed.

  The present invention has been devised in view of these points. Manufacturing method capable of manufacturing a seat cushion material integrated with a surface layer pad and a back layer pad having a density lower than that of the surface layer pad, on the side opposite to the seating surface of the surface layer pad, while suppressing an increase in work man-hours, and its manufacture It is an object to provide a foaming mold for use.

  The first aspect of the present invention is a layered structure in which a surface layer portion disposed on the seating surface side and a back layer portion disposed on the opposite side of the seating surface of the surface layer portion and being harder and less dense than the surface layer portion. A method for manufacturing a seat cushion material having a structure, wherein the back layer portion has a back side surface constituting at least a part of a shape opposite to the seating surface of the seat cushion material, and the seating surface of the seat cushion material The upper die having an upper cavity surface corresponding to the shape on the opposite side and having a constant cross section along the peripheral edge of the back side surface and having a long and linearly deformable linear member disposed thereon A lower layer having a lower cavity surface corresponding to a shape of a seating surface side of the seat cushion material, and a preparation step of attaching a back layer portion by bringing the peripheral edge portion of the back side surface into contact with the linear member; The lower cavity surface has the back layer portion with respect to the lower mold. When the upper mold in the attached state is closed, there are a plurality of protrusions that contact the seating surface side of the back layer portion and press the back layer portion against the upper cavity surface while deforming the linear member. A foamed resin raw material for forming the surface layer portion is placed on the lower cavity surface of the provided lower die, the upper die with the back layer portion attached is closed, the surface layer portion is molded, and the back surface is formed. A molding step that is integrated with the layer portion, and a demolding step that demolds the seat cushion material molded in the molding step.

  According to the first aspect of the present invention, when the foamed resin raw material is foam-molded in a state where the back layer portion is pressed against the upper cavity surface by the protrusion in the molding step, the gap is formed between the peripheral portion of the back side surface and the upper cavity surface. The linear member is deformed and interposed. As a result, even if the foam resin material tries to penetrate between the upper cavity surface and the back side surface of the back layer part during the process of foam curing of the foam resin material, the intrusion is blocked by the linear member, and the back side surface of the back layer part It is possible to suppress the formation of an unnecessary foam on the side.

  According to a second aspect of the present invention, in the first aspect, the linear member is a resin tubular member.

  According to the second invention, since the linear member is a resin tube-like member, it is easily deformed in a direction perpendicular to the longitudinal direction, and the gap between the peripheral portion of the back side surface and the upper cavity surface is sealed and foamed. It is possible to suppress the resin raw material from entering between the back side surface and the upper cavity surface.

  According to a third aspect of the present invention, in the second aspect, the tubular member has a substantially inverted U-shaped groove in which a part of the transverse section is provided on the upper cavity surface and the transverse section opens downward. It is characterized by being fitted in and attached.

  According to the third aspect of the present invention, since the tubular member is attached with a part of its cross-section inserted into the groove, it is prevented from being firmly attached to and detached from the upper cavity surface.

  According to a fourth aspect of the present invention, in the third aspect of the present invention, the groove is formed so that end portions on the opening side are close to each other in a cross section.

  According to the fourth aspect of the present invention, since the cross section of the groove is formed in a constricted shape, the portion in which the tubular member is fitted is further suppressed from separating from the upper cavity surface.

  The fifth aspect of the present invention is a layered structure in which a surface layer portion disposed on the seating surface side and a back layer portion disposed on the side opposite to the seating surface of the surface layer portion and being harder and less dense than the surface layer portion. A foam type for manufacturing a seat cushion material having a structure, wherein the back layer portion having a back side surface constituting at least a part of a shape opposite to a seating surface of the seat cushion material is opposed to the back side surface. It has an upper cavity surface corresponding to the shape opposite to the seating surface of the seat cushion material that can be attached, has a constant cross section along the peripheral edge of the back side surface, and can be elastically deformed long. An upper mold provided with a linear member, and a lower cavity surface corresponding to the shape of the seat cushion surface of the seat cushion material, and the lower layer surface is attached to the back layer portion with respect to the lower mold Before the upper mold in the closed state is closed A lower mold provided with a plurality of protrusions that contact the seating surface side of the back layer portion and press the back layer portion against the upper cavity surface while deforming the linear member, A foamed resin raw material for forming the surface layer portion is introduced onto a cavity surface, the upper mold with the back layer portion attached is closed, the surface layer portion is molded and integrated with the back layer portion. And

  According to the fifth aspect of the present invention, when the foamed resin material is foam-molded with the back layer portion pressed against the upper cavity surface by the protrusion in the foam molding process of the foamed resin material, A linear member is deformed and interposed between the cavity surfaces. As a result, even if the foam resin material tries to penetrate between the upper cavity surface and the back side surface of the back layer part during the process of foam curing of the foam resin material, the intrusion is blocked by the linear member, and the back side surface of the back layer part It is possible to suppress the formation of an unnecessary foam on the side.

  According to a sixth aspect of the present invention, in the fifth aspect, the linear member is a resin tubular member.

  According to the sixth invention, since the linear member is a resin tube-like member, it is easy to be deformed in a direction perpendicular to the longitudinal direction, and the gap between the peripheral portion of the back side surface and the upper cavity surface is sealed and foamed. It is possible to suppress the resin raw material from entering between the back side surface and the upper cavity surface.

  According to a seventh aspect of the present invention, in the sixth aspect of the invention, the tubular member has a substantially inverted U-shaped groove in which a part of the transverse section is provided on the upper cavity surface and the transverse section opens downward. It is characterized by being fitted in and attached.

  According to the seventh aspect of the present invention, the tubular member is attached with a part of its cross-section being fitted into the groove, so that it is prevented from being firmly attached to and detached from the upper cavity surface.

  According to an eighth aspect of the present invention, in the seventh aspect, the groove is formed so that end portions on the opening side are close to each other in a cross section.

  According to the eighth invention, since the groove has a constricted cross section, it is further suppressed that the portion into which the tubular member is fitted is detached from the upper cavity surface.

It is a perspective view of the seat cushion material manufactured with the manufacturing method and foaming mold of one Embodiment of this invention. It is a disassembled perspective view of the seat cushion material which concerns on the said embodiment. It is a top view of the seat cushion material which concerns on the said embodiment. It is sectional drawing cut | disconnected and shown by the IV-IV line of FIG. It is sectional drawing cut | disconnected and shown by the VV line | wire of FIG. It is sectional drawing cut | disconnected and shown by the VI-VI line of FIG. It is sectional drawing which shows the type | mold which shape | molds the seat cushion material which concerns on the said embodiment. 5 shows a cross section corresponding to FIG. The cavity is in a hollow state. It is a figure which expands and shows the VIII part of FIG. It is the top view which looked at the upper model of the model which molds the seat cushion material concerning the above-mentioned embodiment from the cavity side. It is sectional drawing which shows the type | mold which shape | molds the seat cushion material which concerns on the said embodiment. 5 shows a cross section corresponding to FIG. The back layer portion is attached to the upper die and is closed with respect to the lower die. It is sectional drawing which shows the type | mold which shape | molds the seat cushion material which concerns on the said embodiment. 5 shows a cross section corresponding to FIG. The seat cushion material is in a molded state. It is sectional drawing which shows the type | mold which shape | molds the seat cushion material which concerns on the said embodiment. FIG. 7 shows a cross section corresponding to FIG. The seat cushion material is in a molded state. It is a figure which shows the modification corresponding to FIG. 8 in the said embodiment.

  The seat cushion material manufactured with the manufacturing method and foaming mold of one Embodiment of this invention is demonstrated according to FIGS. In each figure, the respective directions of the automobile when the seat cushion material is attached to the automobile floor are indicated by arrows. In the following description, the description regarding the direction is made based on this direction.

  FIG. 1 shows a cushion pad 1 which is a seat cushion material produced by a manufacturing method and a foaming mold according to the present invention. The cushion pad 1 is for a seat cushion of a three-seat bench seat and has a length in the left-right direction that is substantially the same as the width of the passenger compartment. The cushion pad 1 is covered with a cushion cover (not shown) that covers the surface thereof to form a seat cushion. And a seat back (not shown) which has the same composition is combined in the state where it stood up at the rear end part of the seat cushion, and a rear seat is constituted by being attached to the passenger compartment floor. Here, the cushion pad 1 corresponds to a “seat cushion material” in the claims.

  As shown in FIGS. 1-6, the cushion pad 1 has a pair of left and right seat parts 1A and a central seat part 1B disposed between the left and right seat parts 1A. The cushion pad 1 includes a surface layer pad 10 disposed on the front side that is the seating surface side, and a back layer pad 20 disposed on the back side that is the lower side of the surface layer pad 10. Here, the surface layer pad 10 corresponds to the “surface layer portion” in the claims, and the back layer pad 20 corresponds to the “back layer portion” in the claims.

The surface layer pad 10 is formed from a urethane foam obtained by foaming a polyurethane resin, and the density thereof is set to, for example, about 0.05 ± 0.02 g / cm ³ . The surface layer pad 10 includes a surface portion 11 having a shape and an area that occupies the entire seating surface side of the cushion pad 1, and a back surface portion 12 that forms part of the cushion pad 1 on the side opposite to the seating surface. As shown in FIG. 4, the surface layer pad 10 is a portion in which a buttocks support portion 10 a that supports the buttocks of the seated occupant of the left and right seat portions 1 </ b> A supports the thighs of the seated occupants of the left and right seat portions 1 </ b> A. It is formed thicker than the thigh support 10b. This is to improve the sitting comfort by elastically supporting the buttocks support portion 10a having a high seat pressure from the thigh support portion 10b having a low seat pressure. Further, as shown in FIG. 5, in the surface layer pad 10, the buttock support portion 10 c of the central seat portion 1 </ b> B is formed to have a thickness similar to that of the heel support portion 10 a of the left and right seat portions 1 </ b> A. Although not shown, the thickness of the thigh support portion 10d of the central seat portion 1B is thicker than that of the thigh support portion 10b of the left and right seat portions 1A. 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 1A, and a rear end portion and a substantially center in the front-rear direction between the pair of vertical grooves 11a Two lateral grooves 11b are formed to connect each other. The vertical groove 11a and the horizontal groove 11b are formed in a substantially U shape with the cross section opened upward. As shown in FIG. 6, in the portion of the longitudinal groove 11a, the rear hole portion 11a1 is in a portion corresponding to the buttocks support portion 10a, and the front hole portion 11a2 is in a portion corresponding to the thigh support portion 10b. It is formed as a hole reaching the front side portion 21 of the layer pad 20. Both the rear hole portion 11a1 and the front hole portion 11a2 are formed so that the width in the left-right direction is substantially equal to the width in the left-right direction of the vertical groove 11a, and the length in the front-rear direction gradually decreases from the upper end portion toward the lower end portion. Has been. The vertical groove 11a located on the left side (seat inner side) of the right and left seat parts 1A has been described as a representative of the vertical groove 11a, but the rear hole part 11a1 and the front hole part 11a2 are similarly provided for the other vertical grooves 11a. It has been.

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

  As shown in FIGS. 2, 4, and 5, the back layer pad 20 includes a front side portion 21 that contacts a part of the back surface portion 12 of the surface layer pad 10 and a back side portion that forms a part of the back side of the cushion pad 1. 22. As shown in FIG. 4, the back layer pad 20 is a portion in which the buttock support portion 20 a that supports the buttock of the seated occupant of the left and right seat portion 1 </ b> A supports the thigh of the seated occupant of the left and right seat portion 1 </ b> A. It is formed thinner than a certain thigh support part 20b. This is for ensuring a predetermined thickness of the cushion pad 1 corresponding to the thickness of the heel support portion 10a and the thigh support portion 10b of the surface layer pad 10. The back layer pad 20 is provided with a pair of left and right left and right through holes 20c penetrating in the vertical direction toward the outside in the left and right direction (width direction) of the rear part of the left and right seat portion 1A. Further, the back layer pad 20 is provided with one central through hole 20d from the rear part of the central seat part 1B to the inner side of the rear part of the left and right seat parts 1A in the left-right direction (width direction). Thereby, when the surface layer pad 10 is integrally foam-molded with respect to the back layer pad 20, a part of the surface layer pad 10 penetrates into the left and right through holes 20c and the center through hole 20d of the back layer pad 20 and is molded and hardened. A part of the back surface portion 12 of the pad 10 is exposed to form the back side of the cushion pad 1 together with the back side portion 22 of the back layer pad 20. The front side portion 21 of the back layer pad 20 is joined to the back surface portion 12 of the surface layer pad 10 at the time of integral foam molding of the surface layer pad 10. In the back side portion 22 of the back layer pad 20 in a top view, a portion corresponding to the front and rear, left and right outer peripheral portions including the outer peripheral portions of the left and right through holes 20c and the central through hole 20d is formed as a peripheral portion 22a. The peripheral portion 22a is a portion having a width of 10 to 30 mm from the end edge portion. Here, the back side portion 22 corresponds to a “back side surface” in the claims.

  As shown in FIGS. 2, 4 and 5, a frame 23 made of iron wire is inserted inside the front and rear, left and right peripheral portions 22 a of the back layer pad 20. The frame 23 connects the main frame 23a and the front frame 23b with a substantially U-shaped main frame 23a having a front opening when viewed from above, a front frame 23b disposed between the opening portions of the main frame 23a, and the front frame 23b. And two plate-like connecting frames 23c. Furthermore, the frame 23 has one rear locking frame 24a for locking the cushion pad 1 to the vehicle floor, and four front locking frames 24b. The opening side end of the main frame 23a and the left and right ends of the front frame 23b are connected to each other by welding to the connection frame 23c. The rear locking frame 24a is fixed to the main frame 23a by welding, and the front locking frame 24b is fixed to the connection frame 23c by welding. When the back layer pad 20 is formed by foam molding, the main frame 23a, the front frame 23b, and the connecting frame 23c formed in a frame shape are arranged at predetermined positions in the mold, and are integrated by integral foam molding. . The frame 23 has not only a function as a skeleton but also a function of being attracted and held by a magnet embedded in the upper cavity surface when the back layer pad 20 is attached to the upper cavity surface when the cushion pad 1 is formed. Fulfill.

  Based on FIGS. 7-12, the manufacturing method of the cushion pad 1 is demonstrated. In addition, the display of the direction in FIGS. 7-12 shall match the direction of the cushion pad 1. FIG. The back layer pad 20 is formed by olefin resin bead foam molding with the frame 23 inserted in advance. Bead foam molding is a method in which pre-expanded beads are pre-expanded by placing pre-expanded beads obtained by pre-expanding raw material beads, which are impregnated with olefin resin pellets, into a mold cavity and steam heating. It is a molding method that forms a shape along the mold cavity. As shown in FIG. 7, the urethane foam mold 40 for molding the cushion pad 1 includes a lower mold 41 and an upper mold 42 that can be opened and closed with respect to the lower mold 41. The lower mold 41 and the upper mold 42 each have a mold temperature control function for molding urethane foam resin and a lock mechanism (not shown) when the mold is closed. The lower mold 41 is formed with a lower cavity surface 41 a having a shape corresponding to the surface portion 11 of the surface layer pad 10 which is the surface side shape of the cushion pad 1. An upper cavity surface 42 a having a shape corresponding to the shape of the back surface of the cushion pad 1 is formed on the upper mold 42. With the upper mold 42 closed with respect to the lower mold 41, a cavity 43 surrounded by the lower cavity surface 41a and the upper cavity surface 42a is formed between the lower mold 41 and the upper mold 42. Here, the urethane foam mold 40 corresponds to the “manufacturing foam mold” in the claims.

  As shown in FIGS. 7 and 9, the back side portion 22 of the back layer pad 20 on the upper cavity surface 42 a is a portion corresponding to the peripheral portion 22 a of the back layer pad 20 that is opposed to and close to each other with a slight gap. A tube-shaped member 50 made of silicon resin is continuously disposed on a certain mold peripheral portion 42a2. Specifically, as shown in FIG. 8, the tubular member 50 is placed in a substantially inverted U-shaped groove 42 a 1 whose cross section provided in the mold peripheral portion 42 a 2 of the upper cavity surface 42 a opens downward. A part thereof is inserted and fixed in a state where the cross section is deformed. Specifically, the cross section of the groove 42a1 has a bottom wall portion 42a11 and a pair of side wall portions 42a12 extending downward from both ends of the bottom wall portion 42a11. The side wall portions 42a12 approach each other as they go from the bottom wall portion 42a11 to the opening side. It extends to do. Therefore, the width of the opening of the groove 42a1 is narrower than the width of the bottom wall part 42a11, so that the tubular member 50 is not easily detached from the groove 42a1. Here, the tubular member 50 corresponds to a “linear member” in the claims.

  As shown in FIG. 10, the back side portion 22 of the back layer pad 20 is opposed and held close to the upper cavity surface 42 a of the upper mold 42. A plurality of permanent magnets (not shown) are embedded at predetermined positions on the upper cavity surface 42a to attract and hold the frame 23 inserted into the back layer pad 20 by magnetic force. At this time, the tubular member 50 maintains the cross-sectional shape of the unloaded state shown in FIG. 8 and is in contact with the peripheral edge portion 22a of the back side portion 22 of the back layer pad 20, so that the upper cavity surface 42a is magnetically applied. Retained. This step corresponds to the “preparation step” in the claims. The state shown in FIG. 10 is a state in which the upper die 42 to which the back layer pad 20 is attached is closed with respect to the lower die 41. At this time, as shown in FIG. 12, in the portion of the longitudinal groove 11a, the back layer pad 20 is formed on the upper cavity surface by the rear protrusion 41a1 and the front protrusion 41a2 corresponding to the shapes of the rear hole 11a1 and the front hole 11a2. It will be in the state pressed against 42a. Accordingly, the tubular member 50 is elastically deformed into a shape indicated by a two-dot chain line in FIG. 8 by the pressing force applied from the back layer pad 20, and the foamed urethane resin raw material M is formed on the back layer pad 20 in the next molding step. Intrusion between the back side portion 22 and the upper cavity surface 42a is prevented. In this preparation step, a release agent is applied to the upper cavity surface 42a and the lower cavity surface 41a including the surface of the tubular member 50 before attaching the back layer pad 20 to the upper cavity surface 42a of the upper mold 42. The Here, the rear projection 41a1 and the front projection 41a2 respectively correspond to “projections” in the claims.

  As shown in FIG. 12, the rear protrusion 41a1 has an upper base 41a11 on the upper side when viewed from the left-right direction (in side view), and substantially has a lower base 41a12 substantially flush with the lower cavity surface 41a on the lower side. It has a leg trap shape. And the left-right direction is formed in the plate shape of the thickness substantially equal to the groove width of the vertical groove 11a. That is, the outline of the cross section obtained by cutting the rear protrusion 41a1 along a plane substantially parallel to the lower cavity surface 41a corresponding to the seating surface is formed so that the area decreases from the lower bottom 41a12 toward the upper bottom 41a11. . Thus, when the surface layer pad 10 is formed between the lower cavity surface 41 a and the front side portion 21 of the back layer pad 20, the surface layer pad 10 integrated with the back layer pad 20 can be easily removed from the lower mold 41. Become. Although description of the front protrusion 41a2 is omitted, the structure is the same as that of the rear protrusion 41a1, and an upper base 41a21 and a lower base 41a22 are provided corresponding to the upper base 41a11 and the lower base 41a12.

  As shown in FIGS. 11 and 12, the lower die 41 is held as shown in FIG. 10 with the back side portion 22 of the back layer pad 20 facing and held close to the upper cavity surface 42a of the upper die 42. On the other hand, before the upper mold 42 is closed, the foamed urethane resin material M is introduced onto the lower cavity surface 41a of the lower mold 41 to close the mold. Then, the foamed urethane resin raw material M foams and fills the cavity 43 while increasing the volume, and the surface layer pad 10 is formed after a predetermined time for foam curing. FIG. 11 and FIG. 12 show this state, and this process is the “forming process” in the claims. The surface layer pad 10 is formed by this molding process, and the cushion pad 1 is manufactured by being integrated with the back layer pad 20. At this time, as described above, the tubular member 50 is elastically deformed into a shape indicated by a two-dot chain line in FIG. 8 by the pressing force applied from the back layer pad 20, and the foamed urethane resin raw material M is formed on the back layer pad 20. Intrusion between the back side portion 22 and the upper cavity surface 42a is prevented. After that, the upper die 42 is opened with respect to the lower die 41, and the molded cushion pad 1 is removed. This process is the “demolding process” in the claims. Here, the foamed urethane resin raw material M corresponds to the “foamed resin raw material” in the claims.

  In the manufacturing process and the foaming mold as described above, the following effects are exhibited. When the urethane foam raw material M is foam-molded with the back layer pad 20 pressed against the upper cavity surface 42a by the rear protrusion 41a1 and the front protrusion 41a2 in the molding step, the peripheral edge 22a of the back side 22 A tubular member 50 is deformed and interposed between the upper cavity surfaces 42a. As a result, the foamed urethane resin raw material M is prevented from entering by the tubular member 50 even if the foamed urethane resin raw material M attempts to enter between the upper cavity surface 42a and the back side portion 22 of the back layer pad 20 in the process of foaming and curing the foamed urethane resin raw material M. Thus, it is possible to suppress the formation of unnecessary foam on the back side portion 22 of the back layer pad 20.

  Further, the tubular member 50 is easily deformed in a direction perpendicular to the longitudinal direction, and efficiently seals between the peripheral edge portion 22a of the back side portion 22 and the upper cavity surface 42a. And entering between the upper cavity surface 42a. Furthermore, since a part of the cross section of the tubular member 50 is fitted and fixed in the groove 42a1, it is possible to prevent the tubular member 50 from being firmly attached to and detached from the upper cavity surface 42a. In addition, the groove 42a1 extends so that the side wall part 42a12 approaches each other from the bottom wall part 42a11 toward the opening side, so that the tubular member 50 is further unlikely to be detached from the groove 42a1.

  As mentioned above, although specific embodiment was described, this invention is not limited to those structures, A various change, addition, and deletion are possible in the range which does not change the summary of this invention. For example, the following can be mentioned.

  1. In the said embodiment, the tubular member 50 made from a silicon resin was employ | adopted as a linear member. However, the present invention is not limited to this, and other resin tube-like members may be used as long as they can be easily deformed by pressing the back layer pad 20, or a solid linear member made of a foam resin. A linear member or the like may be used.

  2. In the above embodiment, a part of the tubular member 50 is attached to the upper mold 42 by being recessed into the groove 42a1 formed in the upper cavity surface 42a. However, the present invention is not limited to this, and the tubular member 50 or the rubber linear member 51 may be directly attached to the upper cavity surface 42a, or may be mechanically attached by screws or the like. When the rubber-made linear member 51 is disposed in the groove 42a3 having a rectangular cross section formed on the upper cavity surface 42a, the side wall 42a32 of the groove 42a3 is screwed with a screw V as shown in FIG. It can also be installed.

  3. In the above embodiment, the present invention is applied to an automobile seat cushion. However, the present invention may be applied to an automobile seat back or to a seat mounted on an airplane, a ship, a train, or the like.

1 Cushion pad (seat cushion material)
10 Surface pad (surface layer)
20 Back layer pad (back layer)
22 Back side (back layer side)
22a peripheral edge 40 urethane foam mold 41 lower mold 41a lower cavity surface 41a1 rear protrusion 41a2 front protrusion 42 upper mold 42a upper cavity surface 42a1 groove 42a2 mold peripheral part 43 cavity 50 tube-shaped member (linear member)
51 Linear members made of rubber (linear members)
M Foamed urethane resin material (foamed resin material)

Claims (8)

Manufacture of a seat cushion material having a layered structure in which a surface layer portion disposed on the seating surface side and a back layer portion disposed on the side opposite to the seating surface of the surface layer portion and harder and less dense than the surface layer portion are integrated A method,
The back layer portion has a back side surface constituting at least a part of the shape opposite to the seating surface of the seat cushion material,
A linear member having an upper cavity surface corresponding to the shape opposite to the seating surface of the seat cushion material and having a constant cross section along the peripheral edge of the back side surface and capable of elastic deformation is arranged. A preparatory step of attaching the back layer portion to the provided upper mold by bringing the peripheral portion of the back side surface into contact with the linear member; and
A lower mold having a lower cavity surface corresponding to the shape of the seat cushion surface of the seat cushion material, wherein the upper mold is attached to the lower mold with respect to the lower mold. The lower die of the lower mold is provided with a plurality of protrusions that abut against the seating surface side of the back layer portion when pressed and press the back layer portion against the upper cavity surface while deforming the linear member A molding step in which a foamed resin raw material for forming the surface layer portion is introduced onto the cavity surface, the upper mold with the back layer portion attached is closed, the surface layer portion is molded and integrated with the back layer portion; ,
And a demolding step of demolding the seat cushion material molded in the molding step.   It is a manufacturing method of the seat cushion material of Claim 1, Comprising: The said linear member is a manufacturing method of the seat cushion material which is resin-made tube-shaped members.   It is a manufacturing method of the seat cushion material of Claim 2, Comprising: The said tube-shaped member is the substantially reverse U-shape in which the cross section in which a part of the cross section was provided in the said upper cavity surface opened toward the downward direction A method for manufacturing a seat cushion material that is fitted in a groove of the seat cushion.   It is a manufacturing method of the seat cushion material of Claim 3, Comprising: The said groove | channel is a manufacturing method of the seat cushion material formed so that the opening side edge part may mutually adjoin in a cross section. Manufacture of a seat cushion material having a layered structure in which a surface layer portion disposed on the seating surface side and a back layer portion disposed on the side opposite to the seating surface of the surface layer portion and harder and less dense than the surface layer portion are integrated Foam type,
The back layer portion having a back side surface constituting at least a part of the shape opposite to the seating surface of the seat cushion material can be attached with the back side surface facing the seat cushion material. An upper mold having an upper cavity surface corresponding to the shape of the upper die, a long linear member having a constant cross section along the peripheral edge of the back side surface and capable of elastic deformation;
When the seat cushion material has a lower cavity surface corresponding to the shape of the seating surface side, and the lower mold surface is closed when the upper mold with the back layer portion attached to the lower mold is closed. A lower mold provided with a plurality of protrusions that abut against the seating surface side of the back layer portion and press the back layer portion against the upper cavity surface while deforming the linear member;
A sheet in which the foamed resin raw material for forming the surface layer portion is introduced onto the lower cavity surface, the upper mold with the back layer portion attached is closed, the surface layer portion is molded and integrated with the back layer portion Foaming mold for manufacturing cushion materials.   The foaming mold for manufacturing a seat cushion material according to claim 5, wherein the linear member is a tubular member made of resin.   7. The foaming mold for manufacturing a seat cushion material according to claim 6, wherein the tubular member has a substantially inverted U in which a part of a transverse section thereof is provided on the upper cavity surface and opens downward. Foaming mold for manufacturing seat cushion material, which is fitted in a letter-shaped groove. The foaming mold for manufacturing a seat cushion material according to claim 7, wherein the groove is formed such that the opening side end portions thereof are close to each other in a cross section.

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