JP2020188852A - Vehicle seat pad and manufacturing method for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To exert a locking function on a first foam side having no undercut in a concave groove, and even in a concave groove provided in a first foam having a large molding shrinkage, each hook can be easily placed in the concave groove. Provided are a vehicle seat pad that can be inserted and locked, and a method for manufacturing the same. SOLUTION: A pair of standing piece portions 42 are erected apart from a substrate portion 41, and a hook portion 43 is formed at a tip portion of the standing piece portion so as to project to an opposing standing piece portion. The terminal locking clip 4 is used as an insert product, and the pair of standing piece portions 42 and the hook portion 43 are exposed in the concave groove 34 provided on the back surface, and the terminal locking clip 4 is used. The first foam 2 with a clip for locking the terminal, in which the embedded and integrated first foam 3 is foam-molded, and the pair of standing pieces 42 and the hook 43 are exposed on the back surface side. It includes a second foam 6 in which the first foam 2 with a clip for locking the terminal is embedded and integrated to form a foam. [Selection diagram] Fig. 3

Description

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

In the seats for vehicles such as automobiles, the surfaces of the seat cushions and seat pads of the seat backs that form the seats and backrests are covered with a skin such as a fabric skin. A hook is attached to the skin, and the skin covers the surface of the seat pad, and the hook is inserted into a groove provided along the peripheral edge of the back surface of the seat pad to lock the seat pad. It is fixed and held.
By the way, the seat pad, which has been exclusively made of a flexible polyurethane foam molded product, has been moving to replace the back surface side of the seat pad with a first foam material such as expanded polypropylene or expanded polystyrene as a measure for weight reduction in recent years. Then, an invention has been proposed in which the groove portion is provided on the first foam side, and the seat pad surface is covered with the skin by locking the hook attached to the skin to the groove (for example, Patent Document 1). ..

JP-A-2018-1666884

However, in Patent Document 1, an undercut is formed in a groove portion (recessed groove of the present invention) of a second pad portion (“first foam” of the present invention) made of polypropylene foam or the like, which makes its production difficult. There is. As in claim 4, "... in the expanded portion, at least one of the outer inner wall and the inner inner wall is provided with a protruding portion protruding inward of the groove portion", but the protruding portion is undercut. Become. The second pad portion such as polypropylene foam is hard and has shape retention unlike the flexible polyurethane foam molded product having excellent cushioning property, and if there is an undercut, it is difficult to deform and remove the mold, which causes a decrease in yield.

The present invention solves the above problem, and even if the concave groove is provided in the first foam having a large molding shrinkage, the locking function is exerted on the first foam side without undercut in the concave groove. It is an object of the present invention to provide a vehicle seat pad which can be easily inserted into a recessed groove and locked, and a method for manufacturing the same.

In order to achieve the above object, the gist of the invention according to claim 1 is that the first foam is set in a foam molding mold, then a foaming raw material is injected into the foam molding mold and the mold is closed, and then the mold is closed. In a method for manufacturing a vehicle seat pad in which a second foam in which a first foam is embedded and integrated is foam-molded, a pair of standing pieces are erected apart from a substrate portion, and a compatible piece portion is used. An insert product is used as an insert product with a clip for locking the terminal of the epidermis, which has a hook portion formed on the tip portion and a hook portion protruding to the opposite opposing piece, and the pair is formed in the concave groove formed on the back surface of the first foam. The first foam with the terminal locking clip, which is integrally foam-molded with the standing piece portion and the hook portion exposed, is attached to the terminal locking clip and the upper cavity surface of the foam molding mold. A method for manufacturing a vehicle seat pad, which comprises setting the upper mold cavity surface so as to face each other. The method for manufacturing a vehicle seat pad according to claim 2 is the method of claim 1, wherein a plurality of the first foams with clips for locking the terminals are set in each portion of the upper cavity surface, and the plurality of said first foams. The first foam with a clip for locking the terminal is embedded and integrated. The method for manufacturing a vehicle seat pad according to claim 3 is the method of manufacturing the vehicle seat pad according to claim 1 or 2, from the gap between the inner side standing piece portion related to the pair of standing pieces and the inner side standing wall forming the concave groove. In addition, the terminal locking clip that narrows the gap between the outer standing piece portion related to the pair of standing piece portions and the outer standing wall forming the concave groove is integrated to form the first foam. It is characterized by being foam-molded. The method for manufacturing a vehicle seat pad according to the fourth aspect of the present invention is in claims 1 to 3, wherein the second foam is a flexible polyurethane foam molded product, and the first foam is a foam that is lighter than the second foam. It is characterized by being a molded body. The method for manufacturing a vehicle seat pad according to the fifth aspect of the present invention is the method of manufacturing the vehicle seat pad according to the first to fourth aspects, wherein a pair of standing portions are erected apart from the base portion, and the other standing portions are opposed to the respective tip portions of the two standing portions. The clip for the suspension groove of the epidermis on which the hook portion extending to the portion is formed is used as an insert product, and the pair of standing portions and the hook portion are exposed on the top surface side of the first foam, and integrally foamed. The first foam with the clip for the hanging groove and the clip for locking the terminal, which is molded, is set on the upper cavity surface so that the top surface side faces downward, and then the second foam The second foam is foam-molded with the pair of standing portions and the hook portions exposed in a suspension groove provided on the surface of the body.
The gist of the invention according to claim 6 is that a pair of standing pieces are erected apart from the substrate portion, and a hook portion that projects to the opposing standing piece portion is provided at the tip portion of the standing piece portion. The terminal locking clip of the formed skin is used as an insert product, and the pair of standing pieces and the hook are exposed in the concave groove provided on the back surface, and the terminal locking clip is embedded. For terminal locking, with the first foam with a clip for locking the terminal on which the integrated first foam is foam-molded, and the pair of standing pieces and hooks exposed on the back surface side. The seat pad for a vehicle is provided with a second foam having a first foam with a clip embedded and integrally formed by foam molding. The vehicle seat pad according to claim 7, wherein a plurality of first foams with clips for locking terminals are provided, and each standing piece portion and each hook portion are exposed to the back surface side, and a plurality of first foams are provided. The second foam in which the first foam with a clip for locking the terminal is embedded and integrated is foam-molded. The vehicle seat pad according to claim 8 is the vehicle seat pad according to claim 6, wherein the first foam with a clip for locking the terminal has an inward standing piece portion and the concave groove related to the pair of standing pieces. It is characterized in that the gap between the outer side standing piece portion related to the pair of standing pieces and the outer side standing wall forming the concave groove is narrower than the gap between the inner side standing wall to be formed. The vehicle seat pad according to claim 9, wherein the second foam is a flexible polyurethane foam molded product, and the first foam is a foam molded product that is lighter than the second foam. It is characterized by being composed of. The vehicle seat pad according to claim 10, wherein the substrate portion includes an end edge portion that bends and extends from a side edge of a flat main portion according to claims 6 to 9. The vehicle seat pad according to the invention of claim 11 is the seat pad for a vehicle according to claims 6 to 10, wherein a pair of upright portions are erected on the top surface side of the first foam with a clip for locking the terminal at a distance from each other. Clips for hanging grooves on the epidermis, in which hook portions projecting to the opposing standing portions are formed at the tip portions of both standing portions, are integrated with the pair of standing portions and hook portions exposed. As the first foam with a clip for the suspension groove and the clip for locking the terminal on which the first foam is foam-molded, the pair of the second foam is formed in the suspension groove formed on the surface thereof. It is characterized in that the upright portion and the hook portion of the above are exposed, and the first foam with the clip for the hanging groove and the clip for locking the terminal is embedded and integrated to form a foam.

In the vehicle seat pad and the manufacturing method thereof of the present invention, by integrating the terminal locking clip with the first foam, the holding force of the epidermis against the hook can be increased and the epidermis can be securely locked. It exerts excellent effects such as being able to lock the hook easily and smoothly.

It is a back side perspective view of the seat pad for a vehicle of this invention and one form of the manufacturing method thereof. It is a front side perspective view of the seat pad of FIG. FIG. 3 is a sectional view taken along line III-III of FIG. It is a partially enlarged view of FIG. It is a perspective view of the clip for locking the terminal of another aspect. It is explanatory cross-sectional view which forms the 1st foam with a clip for locking a terminal. It is explanatory cross-sectional view which sets the 1st foam molding body with a clip for locking a terminal in an upper mold. After FIG. 7, it is explanatory cross-sectional view which injects a foaming raw material. It is explanatory drawing of the mold closing. It is explanatory cross-sectional view which foam-molded the second foam. It is explanatory sectional view of the seat pad at the time of mold opening. FIG. 3 is a cross-sectional view of another aspect of the seat pad of FIG. 3 to which a clip for a hanging groove is added.

Hereinafter, the vehicle seat pad (hereinafter, also simply referred to as “seat pad”) and the manufacturing method thereof according to the present invention will be described in detail.
1 to 12 are one form of the seat pad of the present invention and a method for manufacturing the same. FIGS. 1 and 2 are perspective views of the seat pad, FIG. 3 is a sectional view taken along line III-III of FIG. 1, and FIG. 4 is FIG. FIG. 5 is a partially enlarged view of the above, FIG. 5 is a perspective view of a terminal locking clip of another aspect, FIG. 6 is an explanatory view for molding a first foam with a terminal locking clip, and FIG. 7 is a first with a terminal locking clip. A cross-sectional view of setting the foam molded product in the upper mold, FIG. 8 is a cross-sectional view of injecting a foaming raw material, FIG. 9 is a cross-sectional view of closing the mold, FIG. A cross-sectional view of the seat pad at the time of opening, FIG. 12 is a cross-sectional view of the seat pad of another aspect. Each figure emphasizes the main part of the invention in order to make the drawing easier to understand, and the terminal locking clip 4 and the hanging groove clip 5 of the skin F and the seat pad P of FIG. 11 (b) omit the hatching of the cross-sectional display. Further, parts not directly related to the present invention will be simplified or omitted.

(1) Vehicle seat pad The vehicle seat pad P (hereinafter, also simply referred to as "seat pad") has a cushion pad and a back pad, but here, a cushion for the rear seat of the vehicle that supports the lower body of a seated occupant. Apply to the pad (Figs. 1 to 4). If this is covered with the skin F to form a seat cushion, the seat back with the skin F covered with the known back pad becomes a rear seat having the auxiliary seat portion 6C in the vehicle width direction.
The seat pad P includes a first foam 3, a terminal locking clip 4 for the skin F, and a second foam 6.

The first foam 3 is a foamed molded product for raising that occupies the lower layer of the seat pad P (FIG. 3). It is lighter than the cushioned second foam 6 (specifically, the apparent density is small), hard (high hardness), and has shape retention. For example, it is composed of a foam molded product obtained by a so-called bead foaming method. It is a block-shaped bead foam formed by pre-foam molding the raw material beads and then in-mold foam molding. The bead foam is preferably expanded polystyrene, expanded polypropylene, expanded polyethylene, or a molded product containing at least one of these. The beaded foam in which the bubbles are sealed inside is harder than the second foam 6 because most of the volume is gas and lightweight, and has hardness and shape retention as a raising member for the seat pad P.

The first foam 3 is foam-molded by embedding and integrating the terminal locking clip 4 of the skin F. The back surface 3b of the first foam is intermittently provided with a plurality of concave grooves 34 having a rectangular cross-sectional shape as shown in FIGS. 1 and 3 and having a substantially equal cross-sectional shape in the longitudinal direction along the peripheral edge thereof. ing. The standing piece portion 42 and the hook portion 43 are exposed in the concave groove 34 formed on the back surface 3b, and the first foam 3 in which the terminal locking clip 4 is integrated is foam-molded.

The terminal locking clip 4 has a pair of standing pieces 42 standing apart from the substrate portion 41, and a hook portion 43 projecting from the tip portion of the standing piece portion 42 to the opposing standing piece portion 42. Are injection-molded products in which each is formed. A molded product made of synthetic resin made of polypropylene resin or the like.
As described in FIG. 4, a trunk portion 45 is raised on a flat main portion 411 of the substrate portion 41 arranged in the concave groove 34, and a plate-shaped standing piece portion 42 branched into two from the trunk portion 45 is upward. This is a terminal locking clip 4 that extends to the tip of the plate and bends to the opposite standing piece 42 at the tip thereof, and the plate-shaped hook 43 projects. The standing piece portion 42 turns diagonally outward and upward on the way from the tip of the trunk portion 45. The hook portion 43 that is horizontally bent inward at the tip of the standing piece portion 42 approaches the tip of the opposing standing wall portion diagonally inward and upward. In the concave groove 34, a gap W1 is secured between the inner standing piece portion 42a (specifically, the most inwardly projecting portion of the plate piece surface) and the inner standing wall 34a forming the concave groove 34. To. A gap W2 is also secured between the outer standing piece portion 42b and the outer standing wall 34b. Here, "inside" refers to the right side of the paper in FIG. 4 and the direction toward the center of the back surface 3b of the first foam.
The board portion 41 has an inclined portion 413 extending diagonally outward from the side edge of the flat main portion 411 whose plate surface is mostly exposed to the bottom of the concave groove 34 to the side opposite to the side where the standing piece portion 42 is located. Further, the edge portion 414 is bent and extends from the side edge of the inclined portion 413. The inclined portion 413 and the edge portion 414 bend and enter the first foam 3 around the concave groove 34 to enhance the anchor effect.

The substrate portion 41, the standing piece portion 42, and the hook portion 43 of the terminal locking clip 4 have an equal cross-sectional shape in the longitudinal direction (the direction perpendicular to the paper surface in FIG. 4), but the standing piece portion 42 and the hook are formed on both end surfaces thereof. Only the substrate portion 41 extends further outward than the end face in the longitudinal direction of the portion 43, forming the surface portion 4110 (see FIG. 5). By providing the surface portion 4110, the standing piece portion 42 and the hook portion 43 secure a gap between the standing piece portion 42 and the hook portion 43 and the end wall 34f (FIG. 1) which connects the pair of standing walls 34a and 34b and surrounds the concave groove 34. , Allows elastic deformation from the solid line position in FIG. 4 to the chain line position.

The terminal locking clip 4 may not have the trunk 45, and may be, for example, the terminal locking clip 4 of another aspect as shown in FIG. In a plan view, a pair of standing pieces 42 are separated from each other and erected outward in a bow shape on a rectangular main part 411. From the tip of the compatible piece 42, each hook 43 descends and inclines toward the opposing piece 42. The substrate portion 41 has an edge portion 414 extending from the flat main portion 411 bent toward the standing piece portion 42 and extends.

The first foam 2 with a terminal locking clip, in which the terminal locking clip 4 is embedded and integrated in the first foam 3, is manufactured by using, for example, a bead foam molding mold T as shown in FIG. .. In the bead foam molding mold T, a rectangular frame portion T2 in a plan view for forming a concave groove 34 is erected on the cavity surface T1, and a columnar holding body T3 is erected in the frame portion T2. The hook portion 43 and the standing piece portion 42 sandwich the top of the holding body T3 from both sides, and the frame opening of the frame portion T2 is covered with the substrate portion 41 to set the terminal locking clip 4. Then, the foamed beads BD pre-foamed for the first foam 3 are injected onto the cavity surface T1 and the first foam 2 with a terminal locking clip is obtained by in-mold foam molding.

Here, one first foam 2 with a terminal locking clip may be used for one seat pad P, but if the first foam 3 becomes longer in the vehicle width direction, it may be divided into a plurality of pieces. It becomes preferable. This is because if the first foam 3 is separated in the vehicle width direction and divided into a plurality of parts, the dimensional error due to the molding shrinkage of the length between both ends of the first foam 3 becomes smaller. Also in this embodiment, the first foam 2 with the terminal locking clip is divided into two in the vehicle width direction. At an intermediate point in the vehicle width direction in a plan view, the first foam 2 with a line-symmetrical terminal locking clip is formed in pairs by being divided into two around a line cut in the vehicle front-rear direction (FIG. 2). The two first foams 2 with terminal locking clips are each provided with four recessed grooves 34.
Such two (plural) first foams 2 with terminal locking clips are integrated with the second foam 6 to form a seat pad P.

The second foam 6 keeps the standing piece portion 42 and the hook portion 43 in each concave groove 34 related to the first foam 2 with the terminal locking clip exposed on the back surface 6b side, and the terminal is locked. It is a foam molded body formed by embedding the first foam 2 with a hook. It has a seat layer 61 having a contact surface portion 611 on the side where the seated occupant comes into contact, and is a cushion body formed of a flexible polyurethane foam molded body. The back surface 3b of the first foam 3 is exposed to form a lower layer for raising, and the second foam 6 is foam-molded by laminating the seat layer 61 on the lower layer. On the surface 6a of the second foam, a suspension groove 69 of the skin F is formed at a boundary portion between the main portion 6A and the side portion 6B of the passenger seat. The seated occupant comes into contact with the contact surface portion 611 via the skin F that covers the seat pad P.

In the seat pad P of the present invention, even if the second foam 6 is integrally foam-molded by embedding the first foam 2 with a clip for locking the terminal, it is formed on the back surface 3b of the first foam on the back surface of the seat pad P. The formed concave groove 34 is exposed as it is, and the pair of standing piece portions 42 and the hook portion 43 are also kept exposed in each concave groove 34 (FIG. 3). Then, in the present embodiment, the gap W2 between the outer side standing piece portion 42b related to the pair of standing piece portions 42 and the outer side standing wall 34b forming the concave groove 34 is formed on the inner side related to the pair of standing piece portions 42. The gap W1 between the standing piece portion 42a and the inner standing wall 34a forming the concave groove 34 is set narrower (FIG. 4). When the hook K of the skin F is inserted between the hooks 43, the hook 43 and the standing piece 42 are once expanded, then closed to sandwich the hook K, and the seat pad P is inserted by the skin F. This is to prevent the hook portion 43 and the standing piece portion 42, which have been closed after being covered, from being inadvertently opened. After the hook portion 43 and the standing piece portion 42 sandwich and hold the hooking tool K, even if an external force pulling the hooking tool K is applied to the skin F and the hooking tool K tries to come off, if the gap W2 with the outer standing wall 34b is narrow. As shown in the chain line shown in FIG. 4, it is possible to prevent the outer standing piece portion 42b from hitting the outer standing wall 34b and the hook K from coming off. The first foam 3 in which the terminal locking clip 4 is embedded and integrated is foam-molded, the first foam 2 with the terminal locking clip is used as an insert product, and the second foam 6 is integrally foam-molded. ing.

As shown in FIGS. 3 and 4, in the second foam 6, the seat layer 61 covers the core pad top surface 3a, and the side peripheral layer 62 covers the side surface 3d of the first foam 3. The upper surface of the seat layer 61 related to the second foam 6 is the design surface on the contact surface portion 611 side with which the seated occupant abuts, and the outer surface of the side peripheral layer 62 is the side design surface of the second foam 6. The second foam 6 covers and integrates with the first foam 3 except for the first foam back surface 3b, which is also the back surface of the seat pad P, to complete the desired seat pad P.
Although not shown, the first foam 3 is provided with a through hole for degassing disclosed in Japanese Patent Application Laid-Open No. 2017-206077, which penetrates from the top surface 3a to the back surface 3b, and further, the back surface 3b side is larger than the hole diameter of the through hole. It has a large depression. In the foam molding of the second foam 6 described later, the second foam 6 fills the through holes and dents, so that the second foam 6 is integrally strengthened with the first foam 3. In the figure, reference numeral 3E indicates a mating portion with the backrest.

FIG. 12 is a seat pad P of another aspect, in which the suspension groove clip 5 of the skin F is added to the seat pad P of FIGS. 1 to 4.
A pair of standing portions 52 are erected separately from each other via the neck portion 55 at the base portion 51, and a hook portion 53 is formed at each tip portion of both standing portions 52 so as to project to the opposing standing portions 52. A clip 5 for a suspension groove of the skin F is further provided. On the back surface 3b side, the pair of standing piece portions 42 and the hook portion 43 related to the terminal locking clip 4 are exposed, and on the top surface 3a side, the pair of standing portions 52 and the hook portion 53 are exposed. The first foam 3 in which the hanging groove clip 5 and the terminal locking clip 4 are embedded and integrated is foam-molded. Instead of the first foam 2 with the terminal locking clip, the first foam 1 with the hanging groove clip and the terminal locking clip is used. Then, in the suspension groove 69 formed on the surface 6a of the second foam, the standing portion 52 and the hook portion 53 are kept exposed, and the second foam 6 has a clip for the suspension groove and a clip for locking the terminal. One foam 1 is embedded and integrated to form a foam, and a desired seat pad P to which a clip 5 for a hanging groove is added is completed. The configuration of the other terminal locking clips 4 and the like is the same as that of the seat pads P of FIGS. 1 to 4, and the description thereof will be omitted.

(2) Manufacturing Method of Seat Pad for Vehicle The seat pad P is manufactured as follows, for example, by adopting the first foam 2 with a clip for locking a terminal as shown in FIGS. 1 to 4. FIG. 11). Using the foam molding mold 7, the second foam 6 in which the contact surface portion 611 on the side where the occupant comes into contact is foam-molded with a flexible polyurethane foam molded body is foam-molded, and the insert product has a terminal locking clip. A vehicle seat pad P integrated with the first foam 2 is manufactured.

Prior to the manufacture of the seat pad P, the first foam 2 with the terminal locking clip and the foam molding mold 7 are prepared. The first foam 2 with a clip for locking the terminal is the same as that described in (1) Seat pad, and detailed description thereof will be omitted. As shown in FIGS. 1 and 2, the first foam 2 with a pair (plurality) of terminal locking clips, which is separated and divided into two at the center of the back surface of the seat pad P in the vehicle width direction and embedded in the second foam 6. Is used.

The foam molding mold 7 is a split mold as shown in FIG. 8, and the lower mold 9 and the upper mold 8 are connected so as to be openable and closable. When the mold is closed, the lower mold cavity surface 91, which is entirely recessed like a bowl to form the design surface of the contact surface portion 611, and the upper mold cavity surface 81, which is aligned with the back surface of the first foam 3, are substantially flat. , A cavity for the seat pad P is formed (Fig. 9). In a set of the first foam 2 with a pair of terminal locking clips on the upper die 8, the portion of the upper die cavity surface 81 corresponding to the terminal locking clips 4 arranged near both ends in the vehicle width direction is The engaging projection 82 is formed. When the mouth between the two hooks 43 is expanded by elastic deformation and the head of the engaging protrusion 82 enters between the standing pieces 42, the terminal locking clip 4 sandwiches the head with an elastic restoring force. It is held by the joint protrusion 82.
In this embodiment, as shown in FIGS. 7 and 11, the engaging protrusions 82 are formed only on two parts of the upper die cavity surface 81 corresponding to the first foam 2 with the terminal locking clips near both ends in the vehicle width direction. Is provided. Of course, if the first foam 2 with the terminal locking clip can be set on the upper mold 8, the engaging projection 82 may be provided at the corresponding portion of the other terminal locking clip 4. The foam molding die 7 molds the seat pad P of FIG. 2 in an inverted shape.

In the manufacturing method of the seat pad, first, the first foam 2 with the terminal locking clip is used under the mold open state, and this is set in the foam molding mold 7. Here, a pair (plurality) of the first foams 2 with a clip for locking the terminal as shown in FIG. 7 are prepared. The first foam 2 with the terminal locking clip is set on each portion of the upper die cavity surface 81 so that the terminal locking clip 4 and the engaging protrusion 82 face each other.

Specifically, in FIG. 7, the terminal locking clip 4 is opposed to the engaging projection 82 with the back surface 3b side of the first foam 3 facing up. By pressing against the engaging protrusion 82, the mouth between the two hooks 43 is opened by elastic deformation, and the head of the engaging protrusion 82 passes between the two hooks 43 and enters between the compatible pieces 42. Then, the mouths of both hooks 43 are closed by the elastic restoring force. The terminal locking clip 4 is inserted into the head of the engaging protrusion 82, and the first foam 2 with the terminal locking clip is locked and set on the upper cavity surface 81. The terminal locking clip 4 and the engaging protrusion 82 have a predetermined length in the direction perpendicular to the paper surface of FIG. 7 and have an equal cross-sectional shape. Therefore, if the terminal locking clip 4 sandwiches the head of the engaging projection 82, the position of the first foam 2 with the terminal locking clip on the upper cavity surface 81 is uniquely determined. It is set automatically. In the set of the first foam 2 with the terminal locking clip to the upper mold 8, the groove mouth of the concave groove 34 accommodating the terminal locking clip 4 is closed by the flat upper mold cavity surface 81 (FIG. 8). The pair of first foams 2 with terminal locking clips are set slightly apart from each other on the upper die cavity surface 81 so that an empty space S is formed between them.

Next, the foaming raw material for the second foam 6 is injected onto the lower mold cavity surface 91 using an injection nozzle NL or the like.
Subsequently, the upper mold 8 is operated to close the mold (FIG. 9). By closing the upper die 8 and the lower die 9, the cavity C for the seat pad P in which the first foam 2 with the terminal locking clip is insert-set is formed. In this embodiment, the mold is closed after the injection of the foaming raw material, but the foaming raw material g can also be injected after the mold is closed.

After closing the mold, the process proceeds to foam molding of the second foam 6. The second foam 6 having the contact surface portion 611 on the design surface side and the inner surface 6b on the opposite side is brought into contact with the top surface 3a of the first foam 3 to form the seat layer 61 is foam-molded. The mold closed state of FIG. 9 is maintained for a predetermined time, and the pair of standing piece portions 42 and the hook portion 43 are kept exposed in the concave groove 34 on the back surface side of the seat pad P, so that the second flexible polyurethane foam molded product is formed. The foam 6 is foam-molded. The contact surface portion 611 is formed on the lower die cavity surface 91, and the second foam 6 is foam-molded by abutting the inner surface 6b on the opposite side of the corresponding surface portion 611 to the top surface 3a of the first foam 3. (Fig. 10). The empty space S is filled with the second foam 6.

In this embodiment, a terminal locking clip in which the gap W2 between the outer standing piece portion 42b and the outer standing wall 34b is narrower than the gap W1 between the inner standing piece portion 42a and the inner standing wall 34a. The second foam 6 is integrally molded by using the first foam 2 with a clip as an insert product. Therefore, the seat pad P in which the gap W2 between the outer standing piece portion 42b and the outer standing wall 34b as shown in FIGS. 4 and 10 is narrower than the gap W1 is formed.

When the foam molding of the second foam 6 is completed and the mold is opened (FIG. 11), a seat pad P having the terminal locking clip 4 and realizing weight reduction by incorporating the first foam 3 can be obtained.
Here, since the first foam 2 with the terminal locking clip is divided into two in the vehicle width direction, even if the shrinkage is large in the molding of the first foam 3, the engaging protrusion of the upper mold 8 is formed. The second foam 6 can be molded while the terminal locking clip 4 is held by 82 (b of FIG. 11). Then, the distance L from the peripheral edge of the seat pad P to the terminal locking clip 4 is always kept constant. Even in the first foam 3 having a large molding shrinkage, the position of the terminal locking clip 4 on the seat pad P is maintained, and the distance L does not fluctuate. The hook K of the skin F can be smoothly inserted into the terminal locking clip 4, and a desired seat pad P can be obtained.
In the figure, reference numeral 3G indicates a first foam having a small molding shrinkage, reference numeral 3B indicates a first foam having a large molding shrinkage, and reference numerals 89 and 99 indicate a molding surface on the lower mold 9 side and the upper mold 8 side.

Further, the present invention has been further developed to replace the first foam 1 with a clip for locking the terminal with the first foam 1 with a clip for hanging groove and a clip for locking the terminal as shown in FIG. The seat pad P can be manufactured by setting it to 8.
On the back surface 3b side, the terminal locking clip 4 becomes an insert product and the first foam 3 is integrally foam-molded, but the hanging groove clip 5 also becomes an insert product and integrally foam-molds on the top surface 3a side. Then, the first foam 1 with a clip for hanging groove and a clip for locking the terminal is manufactured. A suspension in which a pair of standing portions 52 are erected separately from the base portion 51 via a neck portion 55, and a hook portion 53 is formed so as to project to a mating standing portion 52 facing the respective tip portions of both standing portions 52. The first foam 3 is molded using the groove clip 5 as an insert product.

Then, the pair of upright portions 52 and the hook portion 53 are exposed on the top surface 3a side of the first foam 3, and are integrally foam-molded with a clip for a hanging groove and a clip for locking the terminal. The first foam 1 is set on the upper cavity surface 81 so that the top surface 3a side of the first foam 3 faces downward. After that, the second foam 6 is foam-molded so that the pair of standing portions 52 and the hook portions 53 are exposed in the suspension groove 69 provided on the surface 6a of the second foam 6. When the mold is removed, the seat pad P as shown in FIG. 12 is obtained.
In this embodiment, the lower mold 9 of the foam molding mold 7 of FIG. 8 is provided with a ridge portion 96 for a suspension groove. In the manufacture of the seat pad P of FIG. 12, a frame wall portion having substantially the same shape as the rectangular frame portion T2 in the plan view shown in FIG. 6 is located at the portion of the ridge portion 96 facing the hanging groove clip 5 when the mold is closed (shown in the figure). ) Is incorporated. When the mold is closed, the upright portion 52 and the hook portion 53 are housed in the frame of the frame wall portion, and the plate-shaped base portion 51 covers the upper surface opening of the frame wall portion.
Other configurations are the same as those described in (1) Seat pad P, and the description thereof will be omitted. The same code as the code described in (1) indicates the same or equivalent portion.

(3) Effect According to the vehicle seat pad and the manufacturing method thereof configured as described above, the second foam 6 is made into a soft polyurethane foam molded product, and the first foam 3 such as polypropylene foam, which is lighter and harder than this, is formed. By using it, the weight of the seat pad P can be reduced.
Then, the first foam 2 with a terminal locking clip, in which the standing piece portion 42 and the hook portion 43 are exposed on the back surface 3b side in the concave groove 34, is exposed on the back surface 6b side of the standing piece portion 42 and the hook portion 43. When the second foam 6 is formed by burying and integrating in a state, the hook K of the skin F can be locked by using the terminal locking clip 4. As shown in FIG. 3, the arrowhead-shaped head of the hook K is spread between the hook portions 43 and inserted, and the head is sandwiched between the pair of hook portions 43 and the standing piece portion 42 to securely lock the hook. The terminal locking clip 4 embedded and integrated in the first foam 3 is made of a synthetic resin and can be elastically deformed and elastically restored, and the standing piece portion 42 and the hook portion 43 can be expanded and sandwiched. It can be carried out easily and smoothly. By integrating the terminal locking clip 4 with the first foam 3, it is not necessary to form an undercut protruding portion in the groove as in Patent Document 1, and the yield is not lowered. Further, since the terminal locking clip 4 is integrated with the first foam 3 which is harder and has shape retention than the cushioning second foam 6, the standing piece portion 42 and the hook portion 43 are stable. It is held and does not wobble, and can be easily expanded by the locking tool K on the epidermis side.

Further, while Patent Document 1 has a role of accommodating the hook K in the groove and a role of stopping the hook K of the epidermis F at the protruding portion provided on the inner wall of the groove, the present invention has the role of stopping the hook K. Since the terminal locking clip 4 for stopping the hook K of the skin F is provided separately from the concave groove 34 formed in the first foam 3, the concave groove 34 has a cross-sectional view as shown in FIG. It has a very simple rectangular shape, and the circumference of the groove on the back surface 3b of the first foam can be flattened. Therefore, when the first foam 2 with the terminal locking clip is set in the upper mold 8, the groove opening of the concave groove 34 can be easily closed by the flat upper mold cavity surface 81 (FIG. 8). The foaming raw material can be prevented from entering the groove 34 by molding the second foam 6 without any special measures.

In addition, when a plurality of first foams 2 with terminal locking clips are embedded and integrated in the second foam 6, the total length of each first foam 3 is reduced, so that the molding shrinkage is large. Even in the foam 3, the dimensional error from the back surface peripheral edge of the seat pad P to each terminal locking clip 4 becomes small. Since the dimensional error is reduced, the hook K attached to the skin F can be easily locked to the terminal locking clip 4 in the concave groove 34.

Further, if an engaging protrusion 82 is formed on the upper mold 8 and the terminal locking clip 4 is engaged with the engaging protrusion 82 to foam-mold the second foam 6, the terminal locking clip 4 can be formed. A seat pad P with no misalignment is completed. Since the second foam 6 is formed while the terminal locking clip 4 is held by the engaging protrusion 82, the distance L from the peripheral edge of the seat pad P to the terminal locking clip 4 does not change (FIG. 11). B). The terminal locking clip 4 of the seat pad P is kept constant without changing the distance from the back surface peripheral edge of the seat pad P. The terminal locking clip 4, which is the other side for locking the locking tool K of the skin F, solves the problem of misalignment due to molding shrinkage when the first foam 3 is used, and is a product of the product. It is useful for improving the yield and improving the workability of covering the seat pad P with the skin F.

Furthermore, as in the present embodiment, the upper die cavity facing the terminal locking clip 4 in the substantially central region of the vehicle front-rear direction of the first foam 2 with the terminal locking clip divided in the vehicle width direction. When the engaging protrusion 82 is provided on the surface 81, the terminal locking clip 4 sandwiches the engaging protrusion 82, and the first foam 2 with the terminal locking clip is set on the upper mold 8, FIG. The terminal locking clip 4 along the back surface of the seat pad P on the front side of the vehicle and the terminal locking clip 4 along the back surface of the seat pad P on the rear side of the vehicle are not far apart from each other. The dimensional error due to the molding shrinkage of the body 3 does not increase. Therefore, even if a plurality of terminal locking clips 4 are provided on the first foam 3 having molding shrinkage, the hook K can be successfully locked to them, and the hooking tool K can be hooked on the terminal locking clips 4. It is possible to reduce the locking failure of the stopper K.

Further, when the second foam 6 is foam-molded by embedding and integrating the first foam 1 with a clip for a hanging groove and a clip for locking the terminal, the clip 5 for the hanging groove has a shape-retaining property. Since it is integrated with one foam 3, it is stable without wobbling, and the hook K for the suspension groove 69 can be easily locked to the suspension groove clip 5. Further, since the hanging groove clip 5, the terminal locking clip 4, and the first foam 3 are integrated into one component, the seat pad P can be easily manufactured and the component management is excellent.

In the present invention, the present invention is not limited to the one shown in the above embodiment, and various modifications can be made within the scope of the present invention according to the purpose and application. Shape, size, number, material, etc. of the first foam 3, the clip for locking the terminal of the skin F 4, the clip for the suspension groove of the skin F 5, the second foam 6, the foam molding type 7, the seat pad P, etc. Can be selected as appropriate according to the application. Although the embodiment is applied to the cushion pad, it can also be applied to the back pad.

1 First foam with clip for hanging groove and clip for locking terminal 2 First foam with clip for locking terminal 3 First foam 3b Back side 34 Concave groove 4 Clip for locking terminal (terminal locking of epidermis) Clip)
41 Board part 42 Standing piece part 43 Hook part 5 Clip for hanging groove (clip for hanging groove on the epidermis)
6 Second foam 7 Foam molding type 81 Upper mold Cavity surface C Cavity F Skin P Seat pad

Claims (11)

The first foam is set in a foam molding mold, then the foaming raw material is injected into the foam molding mold and the mold is closed, and then the second foam in which the first foam is embedded and integrated is foam molded. In the manufacturing method of seat pads for vehicles
A pair of standing pieces are erected apart from the substrate part, and a clip for locking the terminal of the epidermis is inserted at the tip of the compatible piece, each of which has a hook part that projects to the opposing standing piece. The first product with a terminal locking clip, which is integrally foam-molded with the pair of standing pieces and the hooks exposed in the concave groove formed on the back surface of the first foam. A method for manufacturing a vehicle seat pad, wherein the foam is set on the upper cavity surface of the foam molding mold so that the terminal locking clip and the upper mold cavity surface of the foam molding mold face each other. The first foam with the terminal locking clip is set in each portion of the upper cavity surface, and the second foam with the terminal locking clip is embedded and integrated. The method for manufacturing a vehicle seat pad according to claim 1, wherein the body is foam-molded. Rather than the gap between the inner standing piece portion related to the pair of standing pieces and the inner standing wall forming the concave groove, the outer standing piece portion related to the pair of standing pieces and the concave groove are formed. The method for manufacturing a vehicle seat pad according to claim 1 or 2, wherein the terminal locking clip having a narrowed gap with the outer standing wall to be formed is integrated, and the first foam is foam-molded. The vehicle seat pad according to any one of claims 1 to 3, wherein the second foam is a flexible polyurethane foam molded product, and the first foam is a foam molded product that is lighter than the second foam. Manufacturing method. An insert product is a clip for a suspension groove on the epidermis, in which a pair of standing portions are erected apart from the base and a hook portion is formed so as to project to the opposite standing portion facing the tip portions of both standing portions. The pair of erecting portions and the hook portions are exposed on the top surface side of the first foam, and the first foam with the hanging groove clip and the terminal locking clip is integrally foam-molded. Was set on the upper die cavity surface so that the top surface side was facing downward, and then the pair of upright portions and the hook portion were exposed in a suspension groove provided on the surface of the second foam. The method for manufacturing a vehicle seat pad according to any one of claims 1 to 4, wherein the second foam is foam-molded. A clip for locking the terminal of the epidermis, in which a pair of standing pieces are erected apart from the substrate and hooks are formed at the tip of the standing pieces so as to project to the opposing standing pieces. As an insert product, the pair of standing pieces and the hook are exposed in the concave groove provided on the back surface, and the first foam in which the terminal locking clip is embedded and integrated is foam-molded. The first foam with a clip for locking the terminal and
On the back surface side, the pair of standing pieces and the hook portion are exposed, and the first foam with a clip for locking the terminal is embedded and integrated to form a second foam. A seat pad for vehicles that features this. A plurality of the first foams with clips for locking the terminals were provided, and each standing piece portion and each hook portion were exposed on the back surface side, and the plurality of first foams with clips for locking the terminals were embedded and integrated. The vehicle seat pad according to claim 6, wherein the second foam is foam-molded. The first foam with a clip for locking the terminal has the pair of standing pieces rather than the gap between the inner standing pieces related to the pair of standing pieces and the inner standing wall forming the concave groove. The vehicle seat pad according to claim 6 or 7, wherein the gap between the outer standing piece portion and the outer standing wall forming the concave groove is narrowed. The vehicle according to any one of claims 1 to 3, wherein the second foam is a flexible polyurethane foam molded product, and the first foam is a foam molded product that is lighter than the second foam. Seat pad for. The vehicle seat pad according to any one of claims 6 to 9, wherein the substrate portion includes an edge portion extending by bending from a side edge of a flat main portion. On the top surface side of the first foam with a clip for locking the terminal, a pair of standing portions are erected at a distance from each other at the base, and the tip portions of both standing portions are projected to the opposite standing portions. The clip for the suspension groove of the epidermis on which the hook portion is formed is provided with the clip for the suspension groove in which the pair of standing portions and the hook portion are exposed and the integrated first foam is foam-molded. As the first foam with a clip for locking the terminal,
In the suspension groove formed on the surface of the second foam, the pair of standing portions and the hook portion are exposed, and the first foam with the suspension groove clip and the terminal locking clip is provided. The vehicle seat pad according to any one of claims 6 to 9, wherein the seat pad is embedded and integrally molded by foam molding.

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