JP2019146711A - Seat pad and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a seat pad capable of improving productivity and a method for manufacturing the same. SOLUTION: The seat pad 10 of the present invention has a base portion 20 made of a bead foam molded body integrally fixed to the back side of a pad portion 11 made of a soft thermosetting resin foam. Further, the seat pad 10 is provided with a through hole 21 that penetrates the base portion 20 in the front and back directions, and a porous body 30 that has air permeability and is packed in the through hole 21. The porous body 30 is impregnated and cured with a raw material of a thermosetting resin foam constituting the pad portion 11. [Selection diagram] FIG. 6

Description

  The present invention relates to a seat pad and a manufacturing method thereof.

  The seat pad disclosed in Patent Document 1 has a configuration in which a pad portion made of a polyurethane resin foam covers a base portion made of a polystyrene foam bead foam from the front side. Such a seat pad is manufactured by foam-molding the pad portion in the foam mold while the base portion is set on the upper mold of the foam mold.

JP-A-9-70330 (paragraph [0008], FIG. 1)

  By the way, in the seat pad as described above, since the base portion is made of a material having poor air permeability, when the polyurethane resin is foamed, a gas such as foaming gas or air in the foaming mold is caused to flow into the base portion and the pad portion. In this case, there is a problem that a thin portion is formed in the seat pad, resulting in a poor sitting comfort. On the other hand, it is conceivable to provide a gas vent hole penetrating the base portion. In this case, the polyurethane resin leaked to the outside from the gas vent hole rubs against members around the seat pad, and an abnormal noise is generated. Another problem can occur. For this reason, the conventional seat pad has a problem of low productivity.

  This invention is made | formed in view of the said situation, and aims at provision of the seat pad which can improve productivity, and its manufacturing method.

  In order to achieve the above object, the invention of claim 1 is a seat pad in which a base part made of a bead foam molded body is integrally fixed to the back side of a pad part made of a soft thermosetting resin foam. A through hole penetrating the base portion in the front and back direction, and a porous body having air permeability and being packed in the through hole, and the pad portion on the porous body Is a sheet pad impregnated and cured with the raw material of the thermosetting resin foam.

  According to a second aspect of the present invention, the through hole is provided with a stepped portion that widens the through hole in a stepped manner from the front side to the back side of the base portion, and the porous body includes the through hole. The seat pad according to claim 1, wherein the seat pad is housed in a portion on the back side of the stepped portion.

  The invention according to claim 3 is the seat pad according to claim 1 or 2, wherein the porous body is formed of a foam having an open cell structure.

  The invention of claim 4 is a state in which a base portion made of a bead foam molded body is set on an upper mold of a foam mold, and a raw material of a soft thermosetting resin foam is foam-cured in the foam mold, A method of manufacturing a seat pad that forms a pad portion that covers the base portion from the front side, and forming a through hole penetrating in the front and back direction in the base portion, prior to the formation of the pad portion, And filling the through-hole with a porous body having air permeability.

  The invention according to claim 5 is the method for producing a seat pad according to claim 4, wherein when the pad portion is formed, the porous body is impregnated and cured with the raw material of the thermosetting resin foam.

  According to a sixth aspect of the present invention, a stepped portion is formed in the through-hole to widen the through-hole in a stepped shape from the front side to the back side of the base portion, and the porous body is formed from the through-hole. It is a manufacturing method of the seat pad of Claim 5 accommodated in the part on the back side from a level | step difference part.

  The invention of claim 7 is the seat pad manufacturing method according to any one of claims 4 to 6, wherein a foam having an open cell structure is used as the porous body.

[Invention of claims 1, 4 and 5]
In the present invention, a porous body having air permeability is packed in a through-hole penetrating a base portion made of a bead foam molded body in the front and back direction. Thus, when the base part is set on the upper mold of the foam mold and the pad part is formed by foaming and curing the raw material of the thermosetting resin foam in the foam mold, the thermosetting resin foam The gas accumulated between the base portion and the base portion can flow out to the outside through the through hole, and the occurrence of the lacking portion in the seat pad can be suppressed. Moreover, since the porous body is packed in the through hole, it is possible to suppress the leakage of the thermosetting resin from the through hole to the outside when the pad portion is formed. As described above, according to the present invention, it is possible to suppress the occurrence of a malfunction of the seat pad, and it is possible to improve the productivity of the seat pad.

  Moreover, in the inventions of claims 1 and 5, the porous body is impregnated with the raw material of the thermosetting resin foam constituting the pad portion. Therefore, the foam expansion of the raw material of the thermosetting resin foam that has entered while penetrating into the through-holes during foaming of the pad portion is suppressed in the porous body.

[Inventions of Claims 2 and 6]
In this invention, the raw material of the thermosetting resin foam which comprises a pad part in a porous body is impregnated and hardened. Further, the porous body is accommodated on the back side (that is, the side opposite to the pad portion) from the step portion of the through hole. Therefore, the porous body is caught by the step portion of the through hole, and the pad portion is prevented from coming off from the base portion, so that the stabilization of the pad portion to the base portion can be further improved.

[Inventions of Claims 3 and 7]
ADVANTAGE OF THE INVENTION According to this invention, it becomes easy to adjust the magnitude | size of the bubble of the foam as a porous body at the time of manufacture of a porous body, and a thermosetting resin foam is provided, providing a porous body with air permeability. It becomes easy to make the raw material of the composition difficult to foam and expand. Moreover, since the porous body is a foam, it becomes easy to pack the porous body in the through holes without gaps using elasticity.

(A) Perspective view of seat, (B) Side sectional view of seat pad Enlarged side sectional view around the through hole of the seat pad Side sectional view of the base and the porous body packed in the through hole Side cross-sectional view of a foam mold with the base opened and the base set Side cross-sectional view of the closed mold mold and base (A) Side sectional view around the through hole of the base part during foam molding, (B) Side sectional view of the raw material of the thermosetting resin foam that has entered into the through hole while foaming, (C) Thermosetting Cross-sectional side view of a porous material impregnated with resin foam material Side cross-sectional view of the pad formed in the foam mold

  As shown in FIGS. 1A and 1B, the seat pad 10 according to the present embodiment is applied to a cushion pad used for a seating portion 91 of a seat 90 of a vehicle or the like. The seating portion 91 is formed by covering the seat pad 10 with a cover 93. Hereinafter, in the seat pad 10, a seated person side is referred to as a front side, and a side opposite to the seated person is referred to as a back side as appropriate.

  As shown in FIG. 1B, the seat pad 10 is formed by integrally fixing a base portion 20 to the back side of the pad portion 11. The pad portion 11 is made of a soft thermosetting resin foam, and the base portion 20 is made of a bead foam molded body. As a thermosetting resin foam which comprises the pad part 11, the foam of a polyurethane-type resin etc. are mentioned, for example. Examples of the bead foam molded body constituting the base portion 20 include a polystyrene resin bead foam molded body and a polyolefin resin (polyethylene resin, polypropylene resin, etc.) bead foam molded body.

  A through hole 21 is formed in the base portion 20 so as to penetrate in the front and back direction. Specifically, the base portion 20 has a curved concave surface 26 on the front side facing the pad portion 11, and the through hole 21 opens at the bottom portion 27 of the curved concave surface 26 of the base portion 20. The back side surface of the pad portion 11 has a shape corresponding to the front side surface of the base portion 20 and has a bulging portion 19 corresponding to the curved concave surface 26.

  As shown in FIG. 2, the through hole 21 is provided with a step portion 24 that widens the through hole 21 in a stepped manner from the front side to the back side of the base portion 20, and the front side portion from the step portion 24 is a small hole. In addition to the portion 22, the back side portion of the step portion 24 is a large hole portion 23.

  A porous body 30 is packed in the through hole 21. Specifically, the porous body 30 is disposed in the large hole portion 23. The porous body 30 is made of a foam having an open cell structure, for example, urethane slab. In the present embodiment, the porous body 30 has substantially the same size as the large hole portion 23.

  Here, a part of the thermosetting resin foam constituting the pad portion 11 has entered the through hole 21, and the porous body 30 is impregnated and cured with the raw material of the thermosetting resin foam. Thereby, the porous body 30 is harder than the state in which the raw material of the thermosetting resin foam is not impregnated and hardened, and is harder than the pad portion 11. As a result, the porous body 30 accommodated in the large hole portion 23 of the through hole 21 is easily caught by the small hole portion 22, and the pad portion 11 is prevented from being detached from the base portion 20, so that the pad portion to the base portion 20 is secured. 11 can be further stabilized.

  The seat pad 10 is manufactured as follows. First, the base part 20 through which the through hole 21 is formed is prepared. The through hole 21 may be formed simultaneously with the foam molding of the base portion 20 or may be formed after the foam molding.

  Next, the porous body 30 is packed in the large hole portion 23 of the through hole 21 of the base portion 20 (see FIG. 3). In addition, as the porous body 30, the thing of the cross-sectional area substantially the same as the large hole part 23 may be used, and the thing of a cross-sectional area larger than the large hole part 23 may be used.

  Next, as shown in FIG. 4, the base portion 20 is set on the upper mold 70 </ b> A in the foaming mold 70. At this time, the base portion 20 is set so that the back side surface of the base portion 20 (that is, the surface where the porous body 30 is exposed) faces the upper mold 70A side.

  Then, the raw material 50A of the thermosetting resin foam 50 is injected into the lower mold 70B of the foam mold 70, and the foam mold 70 is closed (see FIG. 5). At this time, in this embodiment, the bottom 27 of the curved concave surface 26 of the base portion 20 is disposed on the uppermost side of the curved concave surface 26.

  Then, the raw material 50 </ b> A of the thermosetting resin foam 50 is foam-cured in the foam mold 70. At this time, as shown in FIG. 6A, when the raw material 50A of the thermosetting resin foam 50 expands and expands due to foaming, a gas such as a foaming gas or air in the foaming mold 70 is changed to the base. It is driven to the vicinity of the portion 20 and is easily confined between the thermosetting resin foam 50 and the base portion 20. In particular, since the base portion 20 has the curved concave surface 26, the gas is easily confined near the bottom portion 27 of the curved concave surface 26. Here, since the through hole 21 is provided in the base portion 20 and the through hole 21 is filled with a porous body 30 having air permeability, the gas is passed through the through hole 21 to the outside (that is, the base portion 20). To the back side). The gas flowing out of the through-hole 21 is air (not shown) arranged on the joint of the upper mold 70A and the lower mold 70B or the inner surface of the foam molding mold 70 (for example, the portion facing the porous body 30). It is discharged from the discharge device or the like to the outside of the foaming mold 70. In FIG. 6A to FIG. 6C, the upper mold 70A is not shown.

  When the raw material 50A of the thermosetting resin foam 50 is further expanded and expanded, it enters into the through hole 21 (see FIG. 6B) and impregnates the porous body 30 (see FIG. 6C). Thereby, the expansion of the raw material 50A of the thermosetting resin foam 50 in the porous body 30 is stopped. When the foam curing of the thermosetting resin foam 50 is completed, the pad portion 11 that covers the base portion 20 from the front side is formed in the foam mold 70 (see FIG. 7). And the base part 20 and the pad part 11 are removed from the foaming mold 70, and the seat pad 10 is completed.

  The configuration of the seat pad 10 and the manufacturing method of the present embodiment have been described above. Next, the effect of this embodiment is demonstrated.

  In the seat pad 10 of the present embodiment, the porous body 30 packed in the through hole 21 that penetrates the base portion 20 made of a bead foam molded body in the front and back direction has air permeability. Thus, when the pad portion 11 is foam-molded in the foam molding die 70 with the base portion 20 set on the upper mold 70A of the foam molding die 70, the breathability of the bead foam constituting the base portion 20 is improved. Even if it is bad, the gas accumulated between the base portion 20 and the pad portion 11 can flow out to the outside through the through hole 21, and it is possible to suppress the occurrence of a lacking portion in the seat pad 10. Further, since the porous body 30 is packed in the through-hole 21, it is possible to suppress the leakage of the raw material 50A of the thermosetting resin foam 50 from the through-hole 21 to the outside during the foam molding of the pad portion 11. Become. As described above, according to the present embodiment, it is possible to suppress the occurrence of defects in the seat pad 10 and improve the productivity of the seat pad 10.

  In addition, in this embodiment, the raw material 50 </ b> A of the thermosetting resin foam 50 constituting the pad portion 11 is impregnated and cured in the porous body 30. Therefore, the foam expansion of the raw material 50 </ b> A of the thermosetting resin foam 50 that has entered while penetrating into the through hole 21 during the foam molding of the pad portion 11 is suppressed in the porous body 30. Thereby, the apparent density and hardness of the thermosetting resin that has entered the porous body 30 are increased, and it is possible to enhance the prevention of the pad portion 11 from coming off from the base portion 20.

  According to this embodiment, it becomes easy to adjust the bubble size of the foam as the porous body 30 at the time of manufacturing the porous body 30, and the porous body 30 is thermally cured while having air permeability. It becomes easy to make the raw material 50A of the porous resin foam 50 difficult to foam and expand. Moreover, since the porous body 30 is a foam, it becomes easy to pack the porous body 30 in a through-hole without gap using elasticity.

[Other Embodiments]
The present invention is not limited to the above-described embodiment. For example, the embodiments described below are also included in the technical scope of the present invention, and various modifications are possible within the scope of the invention other than the following. It can be changed and implemented.

  (1) In the above embodiment, the seat pad 10 may be applied to the back pad used for the backrest portion 92 of the seat 90.

  (2) In the above embodiment, the porous body 30 is composed of a foam having an open-cell structure, but may be composed of a fibrous body such as a nonwoven fabric or felt.

  (3) In the above-described embodiment, the through hole 21 is configured to expand in a stepped shape from the front side to the back side of the base portion 20, but may be configured to expand in a tapered shape.

  (4) In the above embodiment, the through hole 21 may have a uniform cross-sectional area.

  (5) In the above embodiment, the porous body 30 is packed only in a part of the through hole 21 in the penetration direction of the through hole 21, but may be packed in the entire through hole 21.

  (6) In the above embodiment, the size of the porous body 30 may be smaller than that of the large hole portion 23 in the front and back direction of the base portion 20.

  (7) In the manufacturing method of the seat pad 10 of the above embodiment, the porous body 30 may not be impregnated with the raw material 50A of the thermosetting resin foam 50 constituting the pad portion 11.

DESCRIPTION OF SYMBOLS 10 Seat pad 11 Pad part 20 Base part 21 Through-hole 30 Porous body

Claims (7)

A seat pad in which a base portion made of a bead foam molded body is integrally fixed to the back side of a pad portion made of a soft thermosetting resin foam,
A through-hole penetrating the base portion in the front-back direction;
A porous body that has air permeability and is packed in the through hole,
A seat pad in which the porous body is impregnated and cured with a raw material of the thermosetting resin foam constituting the pad portion. The through hole is provided with a step portion that widens the through hole in a stepped manner from the front side to the back side of the base portion,
The seat pad according to claim 1, wherein the porous body is accommodated in a portion of the through hole that is on the back side of the stepped portion.   The seat pad according to claim 1 or 2, wherein the porous body is formed of a foam having an open-cell structure. With the base portion made of the bead foam molded body set on the upper mold of the foam mold, the raw material of the soft thermosetting resin foam is foam-cured in the foam mold to cover the base portion from the front side. A method of manufacturing a seat pad for forming a pad portion,
Forming a through-hole penetrating in the front and back direction in the base portion;
Prior to the formation of the pad portion, a method of manufacturing a seat pad including filling a porous body having air permeability into the through hole.   The manufacturing method of the seat pad of Claim 4 which makes the said porous body impregnate and harden | cure the raw material of the said thermosetting resin foam when forming the said pad part. In the through hole, a stepped portion that widens the through hole in a stepped manner from the front side to the back side of the base portion is formed,
The method for manufacturing a seat pad according to claim 5, wherein the porous body is accommodated in a portion of the through hole on the back side of the stepped portion.   The method of manufacturing a seat pad according to any one of claims 4 to 6, wherein a foam having an open cell structure is used as the porous body.