JP6517036B2 - Vehicle seat pad and method of manufacturing the same - Google Patents

Vehicle seat pad and method of manufacturing the same Download PDF

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JP6517036B2
JP6517036B2 JP2015030977A JP2015030977A JP6517036B2 JP 6517036 B2 JP6517036 B2 JP 6517036B2 JP 2015030977 A JP2015030977 A JP 2015030977A JP 2015030977 A JP2015030977 A JP 2015030977A JP 6517036 B2 JP6517036 B2 JP 6517036B2
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pad
reinforcing cloth
pad body
back surface
mold
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JP2016150223A (en
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松本　真人
真人 松本
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Inoac Corp
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Description

本発明は、車両用座席シートを構成する車両用シートパッド及びその製造方法に関する。   The present invention relates to a vehicle seat pad constituting a vehicle seat and a method of manufacturing the same.

自動車等の車両に搭載される座席シートの座部や背もたれを構成するシートクッションがある。軟質ポリウレタンフォーム等のシートパッドを主構成要素とするが、乗員の着座時に該シートパッドが撓んでシートフレームに擦れ、時に異音が発生したりさらにパッド本体が破れたりすることがある。シートパッドのパッド本体裏面に不織布等の裏当て材を被着して改善が図られているが、裏当て材をパッド本体のキワまで配設するのは難しい。パッド本体裏面のキワまで裏当て材を被着しようとすると、発泡型への裏当て材のセットに高精度を要する。裏当て材の型セットで、パーティングラインのキワまで近づける際、発泡型がこれを挟んでしまうと、発泡成形時のガス抜けにつながる。それゆえ、裏当て材には、その外周縁をパッド本体の裏面外周縁よりも一回り小さくしたものが専ら用いられている。
さらに、例えばシートパッドが座部を構成するクッションパッドでは、車両後方側に近づくにつれ側方部位の張出部２３が低くなることもあって(図１,図２参照)、該張出部２３によるシートフレームへのサポートが得難くなっている。その結果、図５のごとく、パッド本体裏面２ｂの外縁近くに配されるシートフレームＦが、裏当て材３と接するのでなく、シートパッドのパッド本体２が露出する横外方にずれて、該パッド本体２を擦って異音を発生させ、またパッド本体２に直に当たるため亀裂ＣＫし、損傷に至るケースがある。
こうしたことから、上記不具合に取組む発明が提案されている（例えば特許文献１、２）。 There is a seat cushion which constitutes a seat and a backrest of a seat mounted on a vehicle such as an automobile. A seat pad made of flexible polyurethane foam or the like is used as a main component, but when the occupant is seated, the seat pad bends and rubs against the seat frame, sometimes generating noise or further breaking the pad body. Although a backing material such as a non-woven fabric is adhered to the back surface of the pad body of the seat pad for improvement, it is difficult to arrange the backing material up to the wrinkles of the pad body. If it is intended to apply the backing material to the bottom of the pad body, the setting of the backing material to the foam type requires high accuracy. When the foaming mold sandwiches the mold of the backing material to bring it into closeness to the parting line, it leads to degassing during foam molding. Therefore, as the backing material, the one whose circumference is smaller than the circumference of the back surface of the pad body is exclusively used.
Furthermore, for example, in a cushion pad in which the seat pad constitutes a seat, the overhanging portion 23 of the side portion may become lower as the vehicle approaches the rear side (see FIGS. 1 and 2). It is difficult to obtain support for seat frames. As a result, as shown in FIG. 5, the seat frame F disposed near the outer edge of the pad body back surface 2b is not in contact with the backing material 3 but is displaced laterally outward so that the pad body 2 of the seat pad is exposed. There is a case where the pad body 2 is rubbed to generate abnormal noise, and since the pad body 2 is directly hit, the crack CK occurs to cause damage.
From such a thing, the invention which works on the above-mentioned fault is proposed (for example, patent documents 1 and 2).

特開２００５−９５２５６号公報JP 2005-95256 A 特開２０１２−２２８４２２号公報JP, 2012-228422, A

特許文献１は、請求項１で「クッションパッドの裏面側に補強布が一部はみ出した状態に張り付けられるように、前記クッションパッドを前記補強布と一体に発泡成形するクッションパッドの成形方法であって、前記クッションパッドからはみ出させる補強布部分を、前記クッションパッドに対する張付け面とは反対の非張付け面側に折り畳むとともに、前記補強布を第１型の型面に取り外し自在に張付け、前記第１型と第２型とのキャビティで発泡樹脂原液を発泡させて成形するクッションパッドの成形方法。」を提案する。
特許文献２は、「パッド本体にはその外縁部沿いに裏面側へ張り出す立壁状の張出部が形成され、さらに、該張出部の裏面側厚み面にその長手方向に向けて起伏のある凹凸部が形成される一方、不織布は、該凹凸部に対応する不織布外周部に、その外周縁から不織布中央部へ向け短冊状に複数の切込みを入れて短冊状部を複数有する短冊状部付き不織布に加工形成され、さらに、該切込みでできた短冊状部同士が重なり合うか又は短冊状部間が開くことにより形成される曲面で前記凹凸部を覆うようにして、該凹凸部に該短冊状部が被着一体化されてなることを特徴とする車両用シートパッド。」を提案する。 Patent document 1 is the molding method of the cushion pad which foam-molds the said cushion pad integrally with the said reinforcement cloth so that the reinforcement cloth may be stuck in the state which partially protruded to the back surface side of the cushion pad in Claim 1. And the reinforcing cloth portion protruding from the cushion pad is folded to the non-sticking side opposite to the sticking face to the cushion pad, and the reinforcing cloth is removably stuck to the mold surface of the first type; A method of forming a cushion pad, in which the undiluted foam resin solution is foamed and molded in the cavity of the mold and the second mold.
According to Patent Document 2, "the pad main body is formed with an overhang portion in the form of an upright wall projecting to the back side along the outer edge portion, and further, the back surface side thick surface of the overhang portion is uneven in the longitudinal direction A certain uneven portion is formed, while a non-woven fabric is a strip-like portion having a plurality of cut in a strip shape extending from the outer peripheral edge toward the non-woven fabric central portion in the non-woven fabric outer peripheral portion corresponding to the uneven portion The uneven portion is covered with a curved surface which is formed by processing into a non-woven fabric with a slit and the strip-like portions formed by the cutting overlap or the space between the strip-like portions is opened. Vehicle seat pad characterized in that the seat-like portion is integrally attached.

しかし、特許文献１は補強布を折り畳んで第１型の型面に張付けて発泡成形するので、補強布にクセがつく問題がある。しかも、発泡成形で通気性のある補強布に発泡樹脂原液が含浸してしまうと、折り返した部分が含浸した補強布部分とくっついてしまう。さらに剛性の強い補強布を折り返すとその部分が膨らむので、型面へのセットで仮止めが必要となる。さらにいえば補強布を折り返す部分が膨らむので、この部位のパッド厚みが薄くなってしまう問題もある。
また、特許文献２は、不織布を貼着するのをパッド本体のキワに近い凹凸部の領域とするが、裏当て材たる不織布セットの難易度が少し下がる程度で、その作業はシビアできつい。さらにこの製法は、通常、上型型面に不織布の短冊状部をセットしなければならず、不織布の発泡型へのセット作業はさらに困難なものになっている。
斯かる事態に対し、パッド本体裏面の外縁付近の必要箇所に、その外縁よりも水平外方へ突き出す状態で補強布を配置し、両面テープで固定することも対策として考えられる。しかし、両面テープの接着力は弱く、さらに補強布がパッド本体よりも突き出していることから、輸送中、器物等との少しの接触で脱落しやすい。両面テープに代え、ホットメルトによる接着とすれば、新たな設備導入、労力負担、作業時間増等でコスト高になるなどの別の問題が発生する。 However, Patent Document 1 has a problem that the reinforcing cloth has a peculiarity because the reinforcing cloth is folded and attached to the mold surface of the first mold to perform foam molding. In addition, when the foam resin undiluted solution is impregnated into the air-permeable reinforcing cloth by foam molding, the folded portion will stick to the impregnated reinforcing cloth portion. Furthermore, since the part will expand when the stiff reinforcing cloth is folded back, temporary fixing is required for setting on the mold surface. Furthermore, there is also a problem that the pad thickness at this portion becomes thin because the portion at which the reinforcing cloth is folded is expanded.
Moreover, although patent document 2 makes sticking of a nonwoven fabric the area | region of the uneven part close | similar to the Kiwa of a pad main body, the work is severe only in the grade to which the difficulty of the nonwoven fabric set which is a backing material falls a little. Furthermore, in this manufacturing method, usually, it is necessary to set the strip-like portion of the non-woven fabric on the upper mold surface, and the setting operation of the non-woven fabric to the foam type becomes more difficult.
In order to cope with such a situation, it is conceivable to place a reinforcing cloth at a necessary position near the outer edge of the back surface of the pad body so as to protrude horizontally outward from the outer edge and fix it with double-sided tape. However, since the adhesive strength of the double-sided tape is weak and the reinforcing cloth protrudes further than the pad main body, it tends to drop off during transportation with a slight contact with goods or the like. If bonding by hot melt is used instead of double-sided tape, another problem arises such as cost increase due to new equipment introduction, labor burden, increase in working time and the like.

本発明は、上記問題を解決するもので、発泡成形での作業に高い精度を要せず、また作業負担をも軽減し、さらに補強布主部への発泡原料の含浸をなくして、シートフレーム等との擦れによる異音発生防止やパッド本体の破れ防止に優れる車両用シートパッド及びその製造方法を提供することを目的とする。   The present invention solves the above problems, and does not require a high degree of accuracy in the operation of foam molding, and also reduces the work load, and further eliminates the impregnation of the foam material into the main part of the reinforcing cloth, to obtain a seat frame. It is an object of the present invention to provide a vehicle seat pad excellent in prevention of abnormal noise generation due to rubbing with an object, etc. and breakage prevention of the pad body, and a method of manufacturing the same.

上記目的を達成すべく、請求項１に記載の発明の要旨は、発泡体からなるパッド本体と、該パッド本体の発泡成形でその裏面に被着一体化されるシート状裏当て材と、を具備する車両用シートパッドにおいて、前記パッド本体の裏面の外縁寄りに、その発泡成形で、基端部が該裏面よりもパッド本体内へ入り込んで一体化し、主部がパッド本体の裏面から突出した板片状の補強布を、さらに具備し、前記パッド本体の裏面から突出する前記主部の付け根部分に前記裏当て材を配し、且つ該裏当て材のその部位にスリットが形成され、前記補強布が該スリットを貫通して前記パッド本体に一体化されて、該主部が、折り曲げられることにより、その先端部分がパッド本体の裏面外縁よりも外方へ張り出すようにしたことを特徴とする車両用シートパッドにある。請求項２の発明たる車両用シートパッドは、請求項１で、前記補強布の板面が該補強布に近い前記パッド本体の裏面外縁に沿って起立配設され、且つ前記パッド本体の裏面から突出する前記主部の付け根部分の板面領域に、パッド本体の裏面中央部側から該パッド本体の裏面外縁側へ向けて切込んだカット部分が形成されてなることを特徴とする。請求項３の発明たる車両用シートパッドは、請求項１又は２で、前記補強布がプレスフェルトからなることを特徴とする。請求項４の発明たる車両用シートパッドは、請求項１〜３で、前記主部が、その付け根部分から先端に向け、該主部に近い前記パッド本体の裏面外縁側へ傾倒するようにして、前記補強布がパッド本体に一体化したことを特徴とする。
請求項５に記載の発明の要旨は、パッド本体の裏面外縁寄りに位置する型面部位に、この位置から型面外縁までの距離よりも深さが大の溝穴を上型に形成した発泡型を用い、且つ該溝穴の深さよりも長い板片状の補強布を用い、型開状態下、上型型面への裏当て材のセットに伴い、前記溝穴に配される該裏当て材の部位にスリットを形成すると共に、該スリットに該補強布を貫通させて、前記裏当て材のセットと共に、該補強布の基端部を前記溝穴から露出させて、該補強布の主部を溝穴へ挿着保持させ、その後、発泡原料の注入及び型閉じを経て、発泡体からなるパッド本体の裏面側に該裏当て材及び該基端部を一体化させて、該パッド本体を発泡成形し、前記主部の折り曲げにより、該主部の先端部分がパッド本体の裏面外縁よりも外方へ張り出すようにしたことを特徴とする車両用シートパッドの製造方法にある。請求項６の発明たる車両用シートパッドの製造方法は、請求項５で、前記補強布がプレスフェルトからなることを特徴とする。 In order to achieve the above object, the gist of the invention according to claim 1 comprises a pad body made of foam, and a sheet-like backing material that is integrally attached to the back surface of the pad body by foam molding. In the vehicle seat pad, the base end portion of the foam body is formed by foaming into the pad body closer to the outer edge of the back surface of the pad body, and the main portion protrudes from the back surface of the pad body. A plate-like reinforcing cloth is further provided, the backing material is disposed at the root portion of the main portion protruding from the back surface of the pad body, and a slit is formed at that site of the backing material, A reinforcing cloth is integrated with the pad body through the slit, and the main portion is bent so that the tip portion protrudes outward more than the outer edge of the back surface of the pad body. Sea for vehicles In the pad. The vehicle seat pad of the invention according to claim 2 is the vehicle seat pad according to claim 1, wherein the plate surface of the reinforcing cloth is disposed upright along the outer periphery of the back surface of the pad body close to the reinforcing cloth, and from the back surface of the pad body The plate surface area of the root portion of the protruding main portion is characterized in that a cut portion cut from the back surface central portion side of the pad main body toward the back surface outer edge side of the pad main body is formed . The vehicle seat pad of the invention according to claim 3 is characterized in that, in claim 1 or 2, the reinforcing cloth is made of press felt . The vehicle seat pad of the invention according to claim 4 is such that, in claims 1 to 3, the main portion is inclined from the root portion toward the front end toward the outer edge of the back surface of the pad main body near the main portion. The reinforcing cloth is integrated with the pad body .
The gist of the invention according to claim 5 is the foam formed in the upper mold at the mold surface site located closer to the back surface outer edge of the pad body, with a slot having a depth greater than the distance from this position to the mold surface outer edge. Using a mold, and using a plate-like reinforcing cloth longer than the depth of the slot, with the setting of the backing material to the upper mold face under the mold open state, the back face disposed in the slot A slit is formed in the portion of the backing material , and the reinforcing cloth is penetrated through the slit to expose the base end of the reinforcing cloth from the slot together with the set of the backing material, thereby forming the reinforcing cloth The main part is inserted into and held in the slot, and after injection and closing of the foam material, the backing material and the base end are integrated on the back side of the foam pad body, and the pad The body is foam-formed, and the leading end portion of the main portion is more outward than the outer edge of the back surface of the pad body by bending the main portion. Overhang as in the manufacturing method of the vehicle seat pad, characterized in that the. A method of manufacturing a vehicle seat pad according to a sixth aspect of the present invention is characterized in that, in the fifth aspect , the reinforcing cloth is made of press felt .

本発明の車両用シートパッド及びその製造方法は、シートフレーム等との擦れによる異音発生防止やパッド本体の破れ防止に万全な対策を講じることができ、しかも作業性を向上させ且つ低コストで対応できるなど優れた効果を発揮する。   The vehicle seat pad and the method of manufacturing the same according to the present invention can take all possible measures to prevent the generation of abnormal noise due to rubbing with a seat frame or the like and to prevent the tearing of the pad body. Demonstrate excellent effects such as being able to respond.

本発明の車両用シートパッドの一形態で、裏面側から見た斜視図である。It is the perspective view seen from the back side by one form of the vehicle seat pad of this invention. 図１の車両用シートパッドの車両後方部に設けた補強布周りの斜視図である。It is a perspective view around a reinforcement cloth provided in the vehicle back part of the vehicle seat pad of FIG. 図２の補強布の箇所での横断面図である。It is a cross-sectional view in the place of the reinforcement cloth of FIG. 図３のシートパッドをシートフレームに組付けた時の横断面図である。It is a cross-sectional view when the seat pad of FIG. 3 is assembled | attached to a seat frame. 図４で補強布がない状態の説明断面図である。FIG. 5 is an explanatory cross-sectional view of a state in which there is no reinforcing cloth in FIG. 4. 図３に代わるシートパッドの他態様図である。It is another aspect figure of the seat pad which replaces FIG. 型開状態で発泡原料を注入している発泡型の説明断面図である。It is explanatory drawing of the foaming type | mold which is pouring the foaming raw material in a type | mold open state. 上型に裏当て材と補強布をセットする様子を示す説明斜視図である。It is an explanatory perspective view showing signs that a backing material and reinforcement cloth are set to an upper model. 図７,図８の後、型閉じし、発泡成形に向かう発泡型の説明断面図である。FIG. 7 is an explanatory cross-sectional view of a foam mold which is closed after molding and which is directed to foam molding. 発泡成形時の補強布周りの説明断面図である。It is an explanatory sectional view around a reinforcing cloth at the time of foam molding. 図３に代わるシートパッドの別態様図である。It is another aspect of the seat pad which replaces FIG.

以下、本発明に係る車両用シートパッド及びその製造方法について詳述する。図１〜図１１は本発明の車両用シートパッド(以下、単に「シートパッド」ともいう。）及びその製造方法の一形態で、図１はシートパッドを裏面側から見た斜視図、図２は図１の補強布周りの斜視図、図３は図２の補強布の箇所での横断面図、図４は図３のシートパッドをシートフレームに組付けた時の横断面図、図５は図４で補強布がない状態の横断面図、図６は図３に代わるシートパッドの他態様図、図７は型開状態で発泡原料を注入している発泡型の説明断面図、図８は上型に裏当て材と補強布をセットする様子を示す説明斜視図、図９は図７の後、型閉じし、発泡成形に向かう発泡型の説明断面図、図１０は発泡成形時の補強布周りの説明断面図、図１１は図３に代わるシートパッドの別態様図である。尚、図面を判り易くするため、裏当て材及び補強布の厚みを適宜大きく図示し、図７〜図１０の発泡型は要部以外を簡略図示する。   Hereinafter, the seat pad for vehicles concerning the present invention and its manufacturing method are explained in full detail. 1 to 11 show an embodiment of a vehicle seat pad (hereinafter, also simply referred to as a "seat pad") and a method of manufacturing the same according to the present invention, and Fig. 1 is a perspective view of the seat pad as viewed from the back side. 1 is a perspective view around the reinforcing cloth of FIG. 1, FIG. 3 is a cross-sectional view at the reinforcing cloth of FIG. 2, FIG. 4 is a cross-sectional view when the seat pad of FIG. 4 is a cross-sectional view without reinforcement cloth in FIG. 4, FIG. 6 is another embodiment of the seat pad in place of FIG. 3, FIG. 7 is an explanatory cross-sectional view of the foaming mold in which the foam material is injected in the mold opening state, 8 is an explanatory perspective view showing the setting of the backing material and the reinforcing cloth in the upper mold, FIG. 9 is a sectional view of the foaming mold which is closed after molding as shown in FIG. FIG. 11 is an alternative view of the seat pad in place of FIG. 3. In addition, in order to make a drawing intelligible, the thickness of a backing material and a reinforcement cloth is illustrated suitably suitably, and the foaming type | mold of FIGS.

（１）シートパッド
シートパッド１は、背もたれ用のバックパッドや着座した乗員の下半身を受け支えるクッションパッドである。本実施形態は図１〜図４のようなクッションパッドに適用する。クッションパッドに表皮を被せてシートクッションの形にすれば、公知のバックパッドに表皮を被せたバックレストと公知のヘッドレストとで車両用座席シートを形成する。
シートパッド１は、発泡体からなるパッド本体２と、裏当て材３と補強布４とを具備する。 (1) Seat pad The seat pad 1 is a back pad for backrest and a cushion pad for receiving and supporting the lower body of a seated occupant. The present embodiment is applied to a cushion pad as shown in FIGS. When the cushion pad is covered with a skin to form a seat cushion, a seat for a vehicle is formed by a backrest in which the skin is covered with a known back pad and a known headrest.
The seat pad 1 includes a foam pad body 2, a backing material 3 and a reinforcing cloth 4.

パッド本体２は、ポリウレタン材料等の発泡樹脂原料を用いて、座部側クッションパッドの座部形状に成形された発泡成形品である(図１〜図４)。本発明の特徴的部分たる補強布４周りを判り易く図示するため、図１、図２、図７〜図１０のシートパッド１,パッド本体２は、車両に設置される状態と上下逆して描く。
パッド本体２は、図３のように、乗員の臀部及び大腿部を支えるメイン部２１と、該メイン部２１の両側で***して、臀部及び大腿部の側部を支えるサイド部２２とに大別される。 The pad main body 2 is a foam-molded article formed in the seat shape of the seat cushion pad by using a foamed resin material such as polyurethane material (FIGS. 1 to 4). The seat pad 1 and the pad body 2 of FIGS. 1, 2 and 7 to 10 are upside down from the state of being installed in a vehicle so that the surroundings of the reinforcing cloth 4 which is a characteristic part of the present invention can be easily illustrated. Draw.
As shown in FIG. 3, the pad body 2 includes a main portion 21 supporting the buttocks and thighs of the occupant, and a side portion 22 protruding on both sides of the main portion 21 to support the sides of the buttocks and thighs. It is divided roughly.

パッド本体２には、側方部位の外縁沿いに裏面側へ張り出す立壁状の張出部２３が形成される(図１,図２)。パッド本体２に係るサイド部２２の外縁沿いに裏面側へ立壁状の張出部２３が張り出す。パッド本体裏面２ｂの中央域にクッション性を保つ厚み部２６を設けて、中央厚み部２６と張出部２３とで、車両前後方向に走る凹所２ｕが形成される。該凹所２ｕにシートフレームＦを配設するが、張出部２３が構造上、車両後方(図１の左方)となるバックパッドに近づくにつれ低くなっている。したがって、シートフレームＦは車両後方部に位置する部分が横外方にずれ易い傾向にある。符号２４は前方部位の張出相当部で、側方部位の張出部２３とでパッド本体裏面をコ字状に囲む。   The pad main body 2 is formed with an overhang 23 in the form of a standing wall extending along the outer edge of the side portion (FIGS. 1 and 2). An overhanging portion 23 in the form of an upright wall projects to the back side along the outer edge of the side portion 22 related to the pad body 2. A thick portion 26 maintaining cushioning properties is provided in the central region of the pad main body back surface 2b, and a recess 2u which runs in the vehicle longitudinal direction is formed by the central thick portion 26 and the overhanging portion 23. The seat frame F is disposed in the recess 2u, and the seat frame F is lowered as it approaches the back pad which is structurally more backward in the vehicle (leftward in FIG. 1). Therefore, in the seat frame F, the portion located at the rear portion of the vehicle tends to be displaced laterally outward. Reference numeral 24 denotes an overhang equivalent portion of the front portion, and the pad main body back surface is surrounded in a U-shape with the overhang portion 23 of the side portion.

裏当て材３は、パッド本体２の発泡成形で、パッド本体裏面２ｂに被着一体化されるシート状体である。ここでは、パッド本体２の発泡成形でその裏面に被着一体化される不織布とする。製織しないで機械的,化学的,熱的などで繊維を固着したり絡み合わせたりして、シート状にした布になっている。
裏当て材３は、パッド本体裏面２ｂの外縁２ｅにまでくまなく綺麗に設けるとなると、シートパッド製造時の型へのセットに精度を要し且つ作業時間も大幅に増えることから、その大きさがパッド本体２の裏面外周縁よりも一回り小さくなっている。図１のごとく、正常にセットされた裏当て材３の周縁３１はパッド本体２の裏面外縁２ｅよりもパッド本体２の中央寄りに位置して、裏当て材３の周縁３１とパッド本体２の裏面外縁２ｅとの間に、型セットをし易くする余裕代が設けられる(図３)。パッド本体２との一体成形で、裏当て材３をパッド本体裏面２ｂの形成用型面に精度良く合わせてセットしなくても、型閉じで発泡型５に裏当て材３が挟まれず、作業性向上につながっている。なお、作業性向上につながる一方で、このままでは、車両後方側のシートパッド裏面１ｂで、前記余裕代に在るパッド本体２の露出部分にシートフレームＦが当たるケースもでてくる(図５)。 The backing material 3 is a sheet-like body that is integrated with the back surface 2 b of the pad body by foam molding of the pad body 2. Here, a non-woven fabric that is integrally attached to the back surface of the pad body 2 by foam molding is used. Without weaving, the fibers are fixed or entangled mechanically, chemically, or thermally to form a sheet-like cloth.
If the backing material 3 is provided cleanly and completely on the outer edge 2e of the back surface 2b of the pad body, the setting to the mold at the time of manufacturing the seat pad requires accuracy and the working time greatly increases. Is one size smaller than the outer periphery of the back surface of the pad body 2. As shown in FIG. 1, the peripheral edge 31 of the backing material 3 set properly is located closer to the center of the pad body 2 than the back outer edge 2 e of the pad body 2, and the peripheral edge 31 of the backing material 3 and the pad body 2 A margin is provided between the rear surface outer edge 2e to facilitate mold setting (FIG. 3). Even if the backing material 3 is not set precisely on the mold surface of the back surface 2b of the pad body by integral molding with the pad body 2, the backing material 3 can not be caught in the foam mold 5 by mold closing. It leads to the improvement of In addition, while it leads to the improvement of workability, in this case, there is also a case where the seat frame F hits the exposed portion of the pad main body 2 existing in the above-mentioned margin on the seat pad rear surface 1b on the vehicle rear side (FIG. 5) .

補強布４は、前記パッド本体２の発泡成形時に、その裏面２ｂの外縁２ｅ寄りで、基端部４１が該裏面２ｂよりもパッド本体２内へ入り込んで一体化して、主部４２がパッド本体２の裏面２ｂから下方へ突出する板片状体である(図３)。そして、該主部４２を、補強布４に近いパッド本体２の裏面外縁２ｅ側に向けて折り曲げることにより、主部４２の板面がパッド本体裏面２ｂに当接するようにして、主部４２の先端部分４２２がパッド本体２の裏面外縁２ｅよりも水平外方へ張り出す構成とする(図４)。ここで、本発明でいう「下方」、「水平外方」とは、シートパッド１(クッションパッド)が車両に組付けられた状況にある図４で、その紙面の下方、紙面左右の外方向を指す。   When the reinforcing cloth 4 is formed by foaming of the pad main body 2, the base end portion 41 is integrated into the pad main body 2 more than the back surface 2b near the outer edge 2e of the back surface 2b and integrated. It is a plate-like body which protrudes downward from the back surface 2b of 2 (FIG. 3). Then, the main portion 42 is bent toward the back surface outer edge 2 e of the pad main body 2 close to the reinforcing cloth 4 so that the plate surface of the main portion 42 abuts on the pad main surface 2 b. The tip portion 422 is configured to project horizontally outward more than the back surface outer edge 2 e of the pad body 2 (FIG. 4). Here, “downward” and “horizontally outward” in the present invention refer to FIG. 4 in a situation where the seat pad 1 (cushion pad) is assembled to a vehicle. Point to

本実施形態の補強布４は、張出部２３の高さが低くて、シートフレームＦが、ともすればシートパッド１に対し相対的に横外方へずれたり、ずれがなくても、裏当て材３が被着されてないパッド本体２の裏面外縁近くのパッド本体むき出し部分(前記余裕代の部位)にシートフレームＦが当たったりするパッド本体後方部域に設けられる。補強布４の主部４２に係る付け根部分４２１を補強布４に近いパッド本体２の裏面外縁２ｅ(張出部２３の外縁２３ｅ)に沿わせ、且つ板片状補強布４の先端部分４２２が裏面外縁２ｅより外方へ出ないように起立配設される (図３)。   In the reinforcing cloth 4 of the present embodiment, the height of the overhanging portion 23 is low, so that the seat frame F may be displaced to the lateral outside relative to the seat pad 1, or even if there is no deviation. It is provided in the pad main body rear region where the seat frame F hits the pad main body exposed portion (portion of the margin) near the rear surface outer edge of the pad main body 2 where the backing material 3 is not attached. The root portion 421 of the main portion 42 of the reinforcing cloth 4 is placed along the back outer edge 2e (the outer edge 23e of the overhang 23) of the pad body 2 close to the reinforcing cloth 4 and the tip portion 422 of the plate-like reinforcing cloth 4 is It is erected so that it does not go out beyond the back outer edge 2e (Fig. 3).

本補強布４には、パッド本体２の発泡成形で、パッド本体２内へ入り込んで一体化される基端部４１の奥まった基端縁４１１側に、図８ごとくの突出部４１３が形成される。パッド本体２に埋設される基端部４１で、その両側壁の一部を両側外方へ鍔状に張出す突出部４１３が形成される。突出部４１３がアンカー効果を高めて、パッド本体２とこれに埋設される基端部４１との一体強化を図る。シートパッド１の車両への組付け時に、補強布４は図４の鎖線から実線図示のごとく、パッド本体２の裏面外縁２ｅよりも主部４２が水平外方に張り出すよう、該主部４２を折り曲げる。このとき、突出部４１３が在ることで、補強布４がパッド本体２から簡単には抜け出せない構造になる。図示を省略するが、該突出部４１３に代え、パッド本体２に埋設される基端部４１で、その両側壁の一部をＶ字状に切欠くノッチ部を設けて、アンカー効果を高めることもできる。   A protrusion 413 as shown in FIG. 8 is formed on the side of the base end edge 411 of the base end portion 41 integrated into the pad body 2 by the foam molding of the pad body 2 in the reinforcing cloth 4. Ru. At the base end portion 41 embedded in the pad body 2, a projecting portion 413 is formed which overhangs a part of both side walls outward in a bowl shape. The protruding portion 413 enhances the anchor effect, and integrally strengthens the pad body 2 and the base end portion 41 embedded therein. At the time of assembly of the seat pad 1 to the vehicle, the reinforcement cloth 4 is such that the main portion 42 protrudes horizontally outward more than the outer surface 2e of the back surface of the pad main body 2 as shown by the chain line in FIG. Bend. At this time, the presence of the projecting portion 413 makes the reinforcing cloth 4 not easily slipped out of the pad body 2. Although not shown, at the proximal end 41 embedded in the pad main body 2 in place of the projection 413, a notch is formed by cutting a part of both side walls in a V shape to enhance the anchor effect. You can also.

加えて、ここでは、パッド本体２の裏面２ｂから下方へ突出する主部４２の付け根部分４２１に前記裏当て材３を配し、且つ該裏当て材３のその部位に、補強布４が挿通可能なスリット３０を形成する(図８)。スリット３０は、スリット幅Ｗ３０を補強布４の厚みＷ４に略等しくして、付け根部分４２１の横断面形状に合わせるのが好ましい。補強布４が該スリット３０を貫通して、スリット３０周囲の裏当て材３が、補強布４の根元部分を強固に保持し、パッド本体２への補強布４の一体化を強める。スリット３０は、細長切れ込みでもよいが、本実施形態のごとく細長孔からなる方が、パッド本体２への補強布４の一体化増強をより磐石なものにし、より好ましい。   In addition, here, the backing material 3 is disposed at the root portion 421 of the main portion 42 projecting downward from the back surface 2 b of the pad body 2, and the reinforcing cloth 4 is inserted into that portion of the backing material 3. The possible slits 30 are formed (FIG. 8). The slit 30 preferably has a slit width W30 substantially equal to the thickness W4 of the reinforcing cloth 4 so as to conform to the cross-sectional shape of the root portion 421. The reinforcing cloth 4 penetrates the slit 30, and the backing material 3 around the slit 30 firmly holds the root portion of the reinforcing cloth 4 to strengthen the integration of the reinforcing cloth 4 with the pad main body 2. The slits 30 may be elongated slits, but it is more preferable that the slits 30 be formed as elongated holes as in the present embodiment, because the reinforcement of the reinforcing cloth 4 with the pad body 2 is enhanced.

既述のごとく、補強布４は、主部４２を折り曲げ、その先端部分４２２がパッド本体２の裏面外縁２ｅよりも外方へ張り出すようにして、車両に組付けられる。そのため、図３に代えて図６のように、カット部分４３を設けるとより好ましくなる。パッド本体２の裏面下方へ突出する主部４２の付け根部分４２１の板面領域に、パッド本体２の裏面中央部側から該パッド本体２の裏面外縁２ｅ側へ向けて切込んだカット部分４３を形成すると、図６の鎖線図示のごとく、主部４２のより円滑な折曲げが可能になる。主部４２の付け根部分４２１で、パッド本体２の裏面中央部側の板面を略水平に横断し且つ補強布４に近いパッド本体２の裏面外縁２ｅ側へ向けて補強布４の厚みの半分程度にまで切り込んだハーフカットのカット部分４３とすれば、主部４２の付け根部分４２１での折曲げ作業が一層楽になり、さらに好ましくなる。   As described above, the reinforcing cloth 4 is assembled to the vehicle such that the main portion 42 is bent and the tip end portion 422 protrudes outward beyond the back outer edge 2 e of the pad body 2. Therefore, it is more preferable to provide the cut portion 43 as shown in FIG. 6 instead of FIG. In the plate surface area of the root portion 421 of the main portion 42 projecting downward to the back surface of the pad body 2, a cut portion 43 cut from the back surface central portion side of the pad body 2 toward the back surface outer edge 2e of the pad body 2 Once formed, as shown by the broken line in FIG. 6, smoother bending of the main portion 42 is possible. Half of the thickness of the reinforcing cloth 4 toward the back outer edge 2 e side of the pad main body 2 which crosses the plate surface on the back central part side of the pad main body 2 substantially horizontally and is close to the reinforcing cloth 4 at the root portion 421 of the main portion 42 The use of a half-cut portion 43 cut to a certain extent makes the bending operation at the root portion 421 of the main portion 42 easier and more preferable.

本補強布４は、異音防止に機能発揮し、またパッド本体２の発泡成形で、図７のごとく上型７に設けた溝穴７２に主部４２を挿着させて(詳細後述)、そのまま保持できる適度の弾力性，圧縮性に富むものが好ましい。これらを充足するプレスフェルトが補強布４の好適材料となる。
プレスフェルトは、元々は羊毛などの毛を縮絨した繊維製品で、羊毛などの繊維の特殊なウロコ状表面形状を利用して、水分,熱,圧力により繊維同士を絡めてしっかりした厚みのあるシート状に仕上げられている。最近は合成繊維100％のプレスフェルトも登場する。羊毛等でふとん綿状にした積層物に湿度,圧力を加えて強固なシート状体のプレスフェルトを造る。その製法から、前記溝穴７２に挿入されるプレスフェルト製補強布４は、そのクッション性に基づく圧縮で、該溝穴７２に按配よく挿着保持できる。次に述べるシートパッド１の製造方法において、補強布４を上型型面７１に保持させる仮止めを必要としない。プレスフェルト製補強布４による適度の圧縮に伴う反発力で、発泡成形過程中、溝穴７２の内周壁にしっかりと係止保持できる。また、主部４２を折り曲げ、その先端部分４２２をパッド本体２の裏面外縁２ｅよりも張り出す状態にし、シートパッド１の車両組付けで、シートフレームＦと主部４２とが図４のように接触し擦れあっても、プレスフェルトの性状から異音が発生しない。異音防止対策部品として打ってつけの素材になっている。プレスフェルトは地厚でほつれにくく、図８に示すような略矩形に裁断してそのまま使用できる所定厚みのプレスフェルトが市販されているので、一層好ましくなっている。 The main reinforcing cloth 4 functions to prevent noise, and the main part 42 is inserted and attached to the groove hole 72 provided in the upper mold 7 as shown in FIG. It is preferable to be one having a suitable elasticity and compressibility that can be held as it is. A press felt satisfying these requirements is a preferred material for the reinforcing cloth 4.
Press Felt is a fiber product originally made of wool and other wool crimped, and by using the special scale-like surface shape of the wool and other fibers, the fibers are entangled by moisture, heat and pressure, and the thickness is firm It is finished in sheet form. Recently, 100% synthetic fiber felt has also appeared. Humidity and pressure are applied to the cotton-like laminate with wool and the like to make a strong sheet-like press felt. From the manufacturing method, the press felt reinforcing cloth 4 inserted into the slot 72 can be inserted and held in the slot 72 with good compression by compression based on its cushioning property. In the method of manufacturing the seat pad 1 described below, it is not necessary to temporarily hold the reinforcing cloth 4 on the upper mold surface 71. By the repulsive force associated with the appropriate compression by the press felt reinforcement cloth 4, the inner peripheral wall of the slot 72 can be firmly locked and held during the foam molding process. Further, the main portion 42 is bent so that the tip end portion 422 is extended beyond the outer edge 2e of the back surface of the pad main body 2 and the seat frame F and the main portion 42 are as shown in FIG. Even if it contacts and rubs, no noise is generated from the properties of the press felt. It has become a material for hitting as an anti-noise component. The press felt is more preferable because the press felt having a predetermined thickness which can be cut into a substantially rectangular shape as shown in FIG. 8 and can be used as it is commercially available.

図１１は図３に代わる補強布４に関する別態様図である。図１１は補強布４周りのシートパッド１の断面図を示す。主部４２が、その付け根部分４２１から先端に向け、該主部４２に近いパッド本体２の裏面外縁２ｅ側へ傾倒するようにして、補強布４がパッド本体２に一体化したシートパッド１とする。補強布４の主部４２が、シートパッド裏面１ｂから下方へ向け、該補強布４に近いパッド本体２の裏面外縁２ｅ側へ傾くようにする。主部４２が傾くことによって、主部４２の折り曲げを容易にし、図４のシートフレームＦ上へのシートパッド１の組付け作業がスムーズに進む。
図中、符号２７はパッド本体表面２ａ側のメイン部２１とサイド部２２の境界部分で車両前後方向に走る縦溝、符号２３ｕはリクライニングレバー等がパッド本体裏面から張出部２３を横切って外方へ突き出し易くした凹み部分を示す。 FIG. 11 is another embodiment of the reinforcing cloth 4 in place of FIG. FIG. 11 shows a cross-sectional view of the seat pad 1 around the reinforcing cloth 4. A seat pad 1 in which a reinforcing cloth 4 is integrated with the pad body 2 such that the main portion 42 is inclined from the base portion 421 toward the tip and toward the back outer edge 2e of the pad body 2 near the main portion 42. Do. The main portion 42 of the reinforcing cloth 4 is inclined downward from the back surface 1b of the seat pad to the side of the back outer edge 2e of the pad main body 2 near the reinforcing cloth 4. The main portion 42 is inclined to facilitate the bending of the main portion 42, and the assembly work of the seat pad 1 on the seat frame F in FIG. 4 proceeds smoothly.
In the figure, reference numeral 27 denotes a longitudinal groove running in the longitudinal direction of the vehicle at the boundary between the main portion 21 and the side portion 22 on the pad body surface 2a side, and reference numeral 23u denotes a reclining lever etc. The dent part which made it easy to stick out is shown.

（２）シートパッド１の製造方法
シートパッド１の製造方法は、裏当て材３と補強布４と発泡型５とを用いて、例えば図７〜図１０の発泡型５に該裏当て材３、該補強布４をセットした後、発泡原料ｇの注入及び型閉じを経て、図１〜図４のようなシートパッド１を成形する。尚、図１のごとく補強布４を一つ設けるのでもよいが、図７〜図１０では補強布４を二つ設けるシートパッド用発泡型５としている。
裏当て材３と補強布４は、（１）のシートパッド１で述べたものと同様で、その詳細説明を省く。 (2) Method of manufacturing the seat pad 1 The method of manufacturing the seat pad 1 uses the backing material 3, the reinforcing cloth 4 and the foaming mold 5 to form the backing material 3 in the foaming mold 5 of FIGS. After the reinforcing cloth 4 is set, the foam material g is injected and the mold is closed to form the seat pad 1 as shown in FIGS. 1 to 4. Although one reinforcing cloth 4 may be provided as shown in FIG. 1, in FIGS. 7 to 10, a foam pad 5 for seat pad is provided in which two reinforcing cloths 4 are provided.
The backing material 3 and the reinforcing cloth 4 are the same as those described in the seat pad 1 of (1), and the detailed description thereof is omitted.

本シートパッド１の製造方法に用いる発泡型５は、図７〜図１０ごとくの分割型で、上型７(一の分割型)と下型６(他の分割型)とを備える。符号８はヒンジを示す。ヒンジ８を支点にして図７から図９のごとく型閉じすると、全体的にへこみ度合いが大きな下型６の型面６１と一部に凹みを有するもののほぼ平坦な上型７の型面７１とで、パッド本体２に裏当て材３と補強布４の基端部４１が一体化するシートパッド１のキャビティＣをつくる。符号６１ａがメイン部形成部、符号６１ｂがサイド部形成部、符号６１ｃが縦溝用凸部を示す。   The foam mold 5 used in the method of manufacturing the seat pad 1 is a split mold as shown in FIGS. 7 to 10, and includes an upper mold 7 (one split mold) and a lower mold 6 (other split molds). The code | symbol 8 shows a hinge. When the mold is closed as shown in FIGS. 7 to 9 with the hinge 8 as a fulcrum, the mold surface 61 of the lower mold 6 having a large degree of denting and the mold surface 71 of the substantially flat upper mold 7 having a recess in part Then, the cavity C of the seat pad 1 in which the backing material 3 and the base end portion 41 of the reinforcing cloth 4 are integrated is formed in the pad body 2. Reference numeral 61a indicates a main portion forming portion, reference numeral 61b indicates a side portion forming portion, and reference numeral 61c indicates a vertical groove convex portion.

図７〜図１０に示す本製法では、下型６の型面でシートパッド１の表面側が成形され、上型７の型面でシートパッド１の裏面側が成形される。上型７には、パッド本体２の裏面外縁２ｅ寄りに位置する型面部位に、この位置から型面外縁までの距離Ｌ１よりも深さＬ２を大にした溝穴７２が設けられる(図７)。溝穴７２は板片状補強布４のうちで挿着される主部４２と略同形(詳しくは若干小さめ)で、方形板の形をした縦長の空所になっている。溝穴７２の深さＬ２よりも長い板片状の補強布４が用いられ、該溝穴７２に主部４２を挿着すると、上型型面７１から基端部４１が突出し露出状態となる。
上型７と下型６との型閉じで、パッド本体２の外縁沿いに裏面側へ立壁状に張り出す張出部２３用の窪み５０が形成される。ただ、図９は車両後方のバックパッドに近い領域で、前記補強布４を設置する部位での断面図を示しており、張出部２３用の窪み５０は小さい。 In the present manufacturing method shown in FIGS. 7 to 10, the surface side of the sheet pad 1 is formed by the mold surface of the lower mold 6, and the back surface side of the sheet pad 1 is formed by the mold surface of the upper mold 7. The upper mold 7 is provided with a slot 72 whose depth L2 is larger than the distance L1 from this position to the outer surface of the mold surface at the mold surface portion located closer to the outer surface 2e of the pad body 2 (FIG. 7) ). The slot 72 is substantially the same as the main portion 42 of the plate-like reinforcing cloth 4 to be inserted (specifically, slightly smaller), and is a longitudinally-long space in the shape of a rectangular plate. The plate-like reinforcing cloth 4 longer than the depth L2 of the slot 72 is used, and when the main part 42 is inserted into the slot 72, the base end 41 protrudes from the upper mold surface 71 and becomes exposed. .
With the mold closing of the upper mold 7 and the lower mold 6, a recess 50 for the overhanging portion 23 protruding in a standing wall shape along the outer edge of the pad body 2 is formed. However, FIG. 9 is a region near the back pad on the rear side of the vehicle and shows a cross-sectional view at a portion where the reinforcing cloth 4 is installed, and the depression 50 for the overhang portion 23 is small.

前記発泡型５,裏当て材３,補強布４を用いて、シートパッド１が、例えば次のように製造される。
まず、発泡型５を型開状態とする(図７)。次いで、この型開状態の上型７へ裏当て材３と補強布４をセットする。上型型面７１への裏当て材３のセットと共に、補強布４の主部４２を溝穴７２へ挿着保持させる。 The seat pad 1 is manufactured, for example, as follows using the foam mold 5, the backing material 3 and the reinforcing cloth 4.
First, the foam mold 5 is brought into the mold open state (FIG. 7). Next, the backing material 3 and the reinforcing cloth 4 are set to the upper mold 7 in the mold open state. The main portion 42 of the reinforcing cloth 4 is inserted into and held in the slot 72 together with the set of the backing material 3 on the upper mold surface 71.

具体的には、上型７への裏当て材３のセットに先立ち、溝穴７２に配される裏当て材３の部位で、付け根部分４２１の横断面形状に合わせて形成したスリット３０に補強布４を貫通させる(図８)。補強布４の主部４２側をその付け根部分４２１までスリット３０に貫通させた状態にして、該主部４２を溝穴７２に挿入する。溝穴７２の横断面形状は主部４２の横断面形状よりも僅かに小さく設定されている。布地製品で、ある程度圧縮が可能な板片状の補強布４は、少し圧し縮めるようにして、多少きつめの溝穴７２にも差込むことができる。差込んだ後、手を離しても、補強布４の主部４２が溝穴７２内に保持される。上型型面７１に在る溝穴７２から下型６に向け、補強布４の基端部４１が露出状態で、しかも仮止めなしの状態であっても、補強布４が挿着保持され、簡単には抜け落ちない。
特に、板片状にして厚みのある補強布４がプレスフェルトからなると、コシがしかりとしており、且つその適度のクッション性に基づく圧縮で、溝穴７２にスムーズに挿入でき、挿着保持される。また、挿着完了すれば、補強布４は先の圧縮に伴う反発力で溝穴７２の内周壁に挿着保持されるので、仮止め等を要しない。
また、裏当て材３には、図示を省略するが、外周縁付近に適宜間隔で矩形のフェライトシート片が貼着一体化されている。一方、上型型面７１の各フェライトシート片に対応する箇所には図示しない磁石が埋め込まれている。
かくして、裏当て材３はフェライトシート片を磁石に吸着させて上型型面７１に円滑セットでき、補強布４は溝穴７２に少し圧縮状態にさせて挿入しさえすれば、補強布４が有する反発力の自律作用で、溝穴７２に挿着保持されるので、上型型面７１への裏当て材３と補強布４のセットは楽に終えることになる。 Specifically, prior to the setting of the backing material 3 to the upper mold 7, at the portion of the backing material 3 disposed in the groove hole 72, reinforcement is applied to the slit 30 formed in accordance with the cross-sectional shape of the root portion 421 The cloth 4 is penetrated (FIG. 8). The main portion 42 is inserted into the slot 72 with the main portion 42 side of the reinforcing cloth 4 penetrating the slit 30 up to the root portion 421 thereof. The cross sectional shape of the slot 72 is set to be slightly smaller than the cross sectional shape of the main portion 42. The piece of reinforcing cloth 4 in the form of a cloth product, which can be compressed to a certain extent, can also be inserted into the slot 72 of the claws in a slightly compressed manner. After insertion, even if the hand is released, the main portion 42 of the reinforcing cloth 4 is held in the slot 72. The reinforcing cloth 4 is inserted and held from the slot 72 in the upper mold surface 71 to the lower mold 6 even when the base end 41 of the reinforcing cloth 4 is in the exposed state and in the state without temporary tacking. Not easy to fall out.
In particular, when the reinforcing cloth 4 in the form of a thick plate is made of press felt, it is stiff and can be smoothly inserted into the slot 72 by compression based on its appropriate cushioning property, and the attachment is held. . In addition, since the reinforcing cloth 4 is inserted and held on the inner peripheral wall of the slot 72 by the repulsive force associated with the previous compression if the insertion is completed, no temporary fixing or the like is required.
Moreover, although illustration is abbreviate | omitted to the backing material 3, the rectangular ferrite sheet piece is stuck and integrated by the space | interval suitably near the outer periphery. On the other hand, magnets (not shown) are embedded in portions of the upper die surface 71 corresponding to the respective ferrite sheet pieces.
Thus, the backing material 3 allows the ferrite sheet pieces to be attracted to the magnet and can be smoothly set on the upper mold surface 71, and the reinforcing cloth 4 can be inserted into the slot 72 in a slightly compressed state. By the autonomous action of the repulsive force, since it is inserted and held in the slot 72, the set of the backing material 3 and the reinforcing cloth 4 on the upper mold surface 71 is finished easily.

その後、発泡原料ｇの注入及び型閉じを経て、発泡体からなるパッド本体２を、その裏面２ｂに裏当て材３及び補強布４を一体化させるようにして、発泡成形する。
本実施形態は、発泡型５への裏当て材３,補強布４のセット後、型開状態のまま、下型６のキャビティＣを形成する型面６１に注入ホースＮＬ等を使用してパッド本体成形用ウレタン発泡原液等の発泡原料ｇを所定量注入する(図７)。続いて、上型７を作動させ型閉じする(図９)。上型７と下型６との型閉じで、裏当て材３,補強布４がインサートされたシートパッド１用キャビティＣができる。尚、発泡型５への裏当て材３,補強布４のセット後、発泡原料ｇを注入し、その後、型閉じしたが、発泡型５に裏当て材３,補強布４をセットした後、型閉じし、その後、発泡原料ｇを注入することもできる。 Thereafter, through injection and closing of the foam material g, the foam pad body 2 is foam-formed so that the backing material 3 and the reinforcing cloth 4 are integrated on the back surface 2b.
In the present embodiment, after setting the backing material 3 and the reinforcing cloth 4 to the foam mold 5, using the injection hose NL or the like on the mold surface 61 forming the cavity C of the lower mold 6 in the mold open state A predetermined amount of foaming raw material g such as a urethane foam stock solution for molding the main body is injected (FIG. 7). Subsequently, the upper mold 7 is operated to close the mold (FIG. 9). When the upper mold 7 and the lower mold 6 are closed, a cavity C for the seat pad 1 into which the backing material 3 and the reinforcing cloth 4 are inserted is formed. After setting the backing material 3 and the reinforcing cloth 4 to the foaming mold 5, the foam raw material g is injected and then the mold is closed, but after setting the backing material 3 and the reinforcing cloth 4 to the foaming mold 5, It is also possible to close the mold and then inject the foam material g.

前記型閉じの後、パッド本体２の発泡成形に移る。図９の型閉じ状態を所定時間維持し、図１〜図３ごとくパッド本体２を、その裏面２ｂ側に裏当て材３が被着一体化し、且つ主部４２がパッド本体裏面２ｂから下方へ突出し、基端部４１がパッド本体２内へ入り込んで一体化するよう発泡成形して、シートパッド１が造られる。   After the mold closing, the process proceeds to foam molding of the pad body 2. The mold closed state of FIG. 9 is maintained for a predetermined time, and as shown in FIGS. 1 to 3, the pad body 2 is integrated with the backing material 3 on the back surface 2b side. The seat pad 1 is made by being foam-formed so that the base end portion 41 protrudes into and integrates with the pad body 2.

発泡成形過程で、発泡原料ｇが上型型面７１に迫り、裏当て材３に含浸し、さらに溝穴７２内へ進入しようとする。しかし、図１０のごとく溝穴７２とこれに挿着された補強布４の主部４２との隙間が狭いので、発泡原料ｇの進入抵抗が大きく、発泡原料ｇは溝穴７２内へ進出しづらい。溝穴７２の侵入口近くで時間が経過して発泡原料ｇは硬化してしまう。主部４２の主要部に発泡原料ｇの含浸はない。
図１０で、符号ｇ１は発泡原料ｇの補強布４への含浸部分を示し、点在する小さな〇印は裏当て材３と補強布４に発泡原料ｇが含浸した原料部分を模式的に示す。裏当て材３は、全域に亘って発泡原料ｇが含浸して、パッド本体裏面２ｂに被着一体化する。補強布４は、キャビティＣ内に露出する基端部４１と溝穴７２の入り口に近い主部４２の付け根部分４２１に発泡原料ｇが含浸する。パッド本体２内に基端部４１が埋設されることによって該パッド本体２に補強布４が一体化する。 In the foam molding process, the foam material g approaches the upper mold surface 71, impregnates the backing material 3, and tries to enter the slot 72. However, as shown in FIG. 10, the gap between the slot 72 and the main portion 42 of the reinforcing cloth 4 inserted in the slot is narrow, so the penetration resistance of the foam material g is large, and the foam material g advances into the slot 72. It is difficult. As time passes near the entrance of the slot 72, the foam material g hardens. The main part of the main part 42 is not impregnated with the foam material g.
In FIG. 10, the sign g1 indicates the impregnated portion of the foam material g into the reinforcing cloth 4, and the small small 印 marks schematically indicate the raw material portion in which the foam material g is impregnated into the backing material 3 and the reinforcing cloth 4. . The backing material 3 is impregnated with the foam material g over the entire area, and is integrated with the back surface 2b of the pad body. The reinforcing cloth 4 impregnates the base end portion 41 exposed in the cavity C and the base portion 421 of the main portion 42 close to the entrance of the slot 72 with the foam material g. By embedding the base end portion 41 in the pad body 2, the reinforcing cloth 4 is integrated with the pad body 2.

パッド本体２の発泡成形を終え、脱型すれば、メイン部２１,サイド部２２の裏面に不織布の裏当て材３が被着一体化し、さらに補強布４の基端部４１がパッド本体２内へ入り込んで一体化し、主部４２がパッド本体裏面２ｂから下方へ突出した所望のシートパッド１が得られる。主部４２の付け根部分４２１での折り曲げにより、該主部４２の先端部分４２２がパッド本体２の裏面外縁２ｅよりも水平外方へ張り出すシートパッド１が出来上がる。該シートパッド１に図示しない表皮を被せると、車両用座席シートの座部用シートクッションになる。
図中、符号６９は下型６の型合せ面、符号７９は上型７の型合せ面を示す。 When the foam molding of the pad body 2 is completed and removed, the backing material 3 of non-woven fabric is integrally attached to the back surfaces of the main portion 21 and the side portion 22, and the base end portion 41 of the reinforcing cloth 4 is inside the pad body 2. A desired seat pad 1 is obtained in which the main part 42 protrudes downward from the back surface 2b of the pad main body by intruding and integrating. By bending the base portion 421 of the main portion 42, the seat pad 1 in which the tip end portion 422 of the main portion 42 protrudes horizontally outward more than the back outer edge 2e of the pad body 2 is completed. When the seat pad 1 is covered with a skin (not shown), it becomes a seat cushion for a seat of a vehicle seat.
In the figure, reference numeral 69 denotes a mold mating surface of the lower mold 6, and reference numeral 79 denotes a mold mating surface of the upper mold 7.

（３）効果
このように構成した車両用シートパッド１及びその製造方法によれば、パッド本体２に基端部４１が一体化し、主部４２がパッド本体２の裏面２ｂから下方へ突出した補強布４を備え、主部４２を折り曲げると、その先端部分４２２をパッド本体２の裏面外縁２ｅよりも水平外方へ張り出すので、補強布４が在る領域では、車両組付け時のシートフレームＦに図４のごとく補強布４が当たることとなり、パッド本体２を傷めない。裏当て材３の被着が難しいパッド本体裏面２ｂの外縁２ｅ付近(前記余裕代の領域)でシートフレームＦが当たる箇所や、張出部２３の高さが低くてシートフレームＦが横外方へずれ易い車両後方部に本補強布４を設けるだけで、異音発生やパッド本体２の破れを防止できる。
特許文献２と違って、裏当て材３に短冊状部を形成し、さらにシートパッド１を造る際、発泡成形での裏当て材３の型面セット作業時に、張出部２３の裏面側厚み面にまで短冊状部を被着するといった高い精度を要しない。裏当て材３はパッド本体２の裏面外周縁よりも一回り小さくでき、裏当て材３の周縁とパッド本体２の外縁との間に余裕代を設けることができるので、上型７への裏当て材３のセットが楽で、従来通り作業性向上が維持される。これに伴う車両へのシートパッド１の組付けで、余裕代があるパッド本体２の露出部分にシートフレームＦが当たる不具合は、補強布４の主部４２がパッド本体２の裏面外縁２ｅよりも水平外方へ張り出して、シートフレームＦが当たるはずだった箇所を主部４２が覆い、代わって、該主部４２がシートフレームＦと当たって不具合を解消する(図４)。補強布４がない場合の図５のごとく、余裕代の領域にあるパッド本体２に、シートフレームＦが直に接して亀裂ＣＫを生んだり、裂けたりする不具合に至らない。ハガレ面２８ができてしまう不具合もない。 (3) Effects According to the vehicle seat pad 1 configured as described above and the method for manufacturing the same, the base end portion 41 is integrated with the pad body 2 and the main portion 42 is reinforced downward projecting from the back surface 2 b of the pad body 2 Since the cloth 4 is provided and the main portion 42 is bent, the tip end portion 422 protrudes outward more horizontally than the back outer edge 2e of the pad body 2, so in the region where the reinforcing cloth 4 is present, the seat frame at the time of vehicle assembly As shown in FIG. 4, the reinforcing cloth 4 hits F, and the pad body 2 is not damaged. Where the seat frame F hits in the vicinity of the outer edge 2e of the back surface 2b of the pad body 3 where the backing material 3 is difficult to adhere (area of the margin), the height of the overhang 23 is low and the seat frame F is laterally outward By providing the main reinforcing cloth 4 in the vehicle rear portion which is easily shifted, it is possible to prevent the generation of abnormal noise and the tearing of the pad body 2.
Unlike Patent Document 2, when forming a strip-like portion on the backing material 3 and forming the sheet pad 1, the thickness of the back surface side of the overhanging portion 23 at the time of setting the mold surface of the backing material 3 in foam molding. It does not require high accuracy such as applying a strip to the surface. Since the backing material 3 can be made one size smaller than the outer periphery of the back surface of the pad body 2 and a margin can be provided between the periphery of the backing material 3 and the outer edge of the pad body 2, the back surface to the upper mold 7 The setting of the backing material 3 is easy, and the improvement of the workability is maintained as before. Due to the assembly of the seat pad 1 to the vehicle accompanying this, the problem that the seat frame F hits the exposed part of the pad body 2 with a margin is that the main portion 42 of the reinforcing cloth 4 is larger than the back outer edge 2e of the pad body 2 The main portion 42 covers the portion where the seat frame F was supposed to hit by projecting horizontally outward, and instead, the main portion 42 hits the seat frame F to solve the problem (FIG. 4). As shown in FIG. 5 in the case where there is no reinforcing cloth 4, the seat frame F is in direct contact with the pad main body 2 in the area of the margin, and does not lead to a problem of causing a crack CK or tearing. There is no problem that the peeling surface 28 is produced.

しかも、補強布４は主部４２を溝穴７２へ挿着保持させた状態にして、パッド本体２の発泡成形が行われるので、溝穴７２内へ発泡原料ｇが侵入し難く、主部４２は付け根部分４２１しか発泡原料ｇの含浸部分がない。シートフレームＦが当たる主部４２の主要箇所に発泡原料ｇの含浸部分がないことから、シートフレームＦ等との擦れによる異音発生を効果的に解消できる。   Moreover, since the reinforcing cloth 4 is in a state where the main part 42 is inserted into and held in the slot 72 and the foam molding of the pad main body 2 is performed, the foam material g hardly penetrates into the slot 72. Only the root portion 421 has no impregnated portion of the foam material g. Since there is no impregnated part of the foam material g at the main part of the main part 42 to which the seat frame F hits, generation of noise due to rubbing with the seat frame F etc. can be effectively eliminated.

そして、特許文献１のように「クッションパッドに対する張付け面とは反対の非張付け面側に折り畳む」ことなく、板片状補強布４はその板状のまま溝穴７２に挿着するので、補強布４にクセがつく問題もない。また、特許文献１は補強布４を折畳むことによって折り返す部分が膨らみ、シートパッド１の製造時、型面へのセットで仮止めが必要になっているが、本シートパッド１は、補強布４の主部４２を溝穴７２へ差し込むだけで、挿着保持させることができるので、仮止めが不要で、発泡成形での作業負担をも軽減している。
特に、異音防止に性能発揮し、さらにパッド本体２の発泡成形で上型７に設けた溝穴７２に主部４２を挿入させて、そのまま保持できる適度の弾力性，圧縮性に富むプレスフェルトが補強布４として用いられると、主部４２を溝穴７２へ円滑に差し込むことができ、且つ発泡成形中、補強布４をそのまま溝穴７２に安定して挿着保持させることができ、作業負担を一層軽減できる。
さらにいえば、補強布４を折畳むことがないので、折畳む部位でパッド本体２の厚みが薄くなることもない。 Then, as in Patent Document 1, the sheet-like reinforcing cloth 4 is inserted into the slot 72 as it is, without being "folded on the side opposite to the side to which the cushion pad is attached". There is no problem that the cloth 4 has a habit. Further, in Patent Document 1, the fold-back portion of the reinforcing cloth 4 swells, and when the sheet pad 1 is manufactured, temporary fixing is required by setting on the mold surface, but the sheet cloth 1 is not the reinforcing cloth. By inserting the main portion 42 of 4 into the groove hole 72, the insertion and holding can be performed, so that temporary fixing is unnecessary and the work load in foam molding is also reduced.
In particular, the press felt is rich in moderate elasticity and compressibility, which can exhibit performance to prevent abnormal noise, and further insert the main portion 42 into the slot 72 provided in the upper mold 7 by foam molding of the pad body 2 and hold it as it is. The main part 42 can be smoothly inserted into the slot 72, and the reinforcement cloth 4 can be stably inserted and held in the slot 72 as it is during foam molding. The burden can be further reduced.
Furthermore, since the reinforcing cloth 4 is not folded, the thickness of the pad main body 2 is not reduced at the folding portion.

また、パッド本体２の発泡成形時に、仮に主部先端部分４２２がパッド本体２の裏面外縁２ｅよりも水平外方へ張り出すようセットすれば、発泡型５が主部４２を挟んでガス抜けが起こるが、本発明はパッド本体２の裏面から主部４２が下方へ突出するようにしてパッド本体２を発泡成形し、その後、主部４２の付け根部分４２１で折り曲げて主部先端部分４２２をパッド本体２の裏面外縁２ｅよりも水平外方へ突き出させて、車両に組込むので、シートパッド１の製造で、発泡型５が主部４２を挟むことによるガス抜けは起こらない。   In addition, if the main portion tip portion 422 is set so as to protrude horizontally outward more than the back surface outer edge 2 e of the pad main body 2 at the time of foam molding of the pad main body 2, the foam die 5 sandwiches the main portion 42 and gas escapes. Although this occurs, the present invention foam-molds the pad body 2 so that the main portion 42 protrudes downward from the back surface of the pad body 2 and then bends at the root portion 421 of the main portion 42 to pad the main portion tip portion 422 Since it is made to project horizontally outward beyond the outer surface 2e of the back surface of the main body 2 and is incorporated in the vehicle, gas escape due to the foam mold 5 sandwiching the main portion 42 does not occur in the manufacture of the seat pad 1.

また、シートパッド１は、別体の補強布をパッド本体２の裏面外縁２ｅよりも水平外方へ突き出す状態にして、その必要接着箇所に両面テープ等で止めるのと違って、発泡成形を終えた製品段階では、パッド本体２の下方に主部４２が突出する状態にあるので、設置スペースをとらない。さらに、両面テープによる接着部材やホットメルトによる接着用の新たな設備、接着に要する作業負担もなしで済み、且つ補強布４のインサートによりパッド本体２と一体成形されるので、両者の結合力は強い。   Also, unlike the case where the seat pad 1 has a separate reinforcing cloth protruding horizontally outward beyond the outer edge 2e of the back surface of the pad body 2 and is stopped with double-sided tape etc. In the product stage, since the main portion 42 protrudes below the pad body 2, no installation space is taken. Furthermore, there is no need for new adhesive equipment with double-sided adhesive tape or new equipment for adhesion with hot melt, and work load required for adhesion, and since it is integrally molded with the pad body 2 by the insert of the reinforcing cloth 4, the bonding force between both is strong.

しかも、パッド本体２内へ入り込む基端部４１の基端縁４１１側に突出部４１３を設けるので、主部４２を折り曲げても、突出部４１３がアンカー効果を発揮して、補強布４がパッド本体２から抜け出ないようになっている。
裏当て材３のその部位に、補強布４の付け根部分４２１の横断面形状に合わせたスリット３０が形成され、補強布４がスリット３０を貫通してパッド本体２に一体化されると、裏当て材３が補強布４の付け根部分４２１を取り巻くので、その付け根部分４２１を強固に保持し、パッド本体２への補強布４の一体化をより確実なものにする。加えて、前述のごとく、補強布４の付け根部分４２１は発泡成形で、裏当て材３と一緒に発泡原料ｇが含浸して硬化するので、付け根部分４２１では補強布４と裏当て材３とが一体化することになり、補強布４のパッド本体２からの抜け落ち防止対策が完璧となる。品質の安定維持が図られる。 Moreover, since the protrusion 413 is provided on the side of the base end edge 411 of the base end 41 entering the pad body 2, the protrusion 413 exerts an anchor effect even when the main portion 42 is bent, and the reinforcing cloth 4 is a pad. It does not get out of the main body 2.
When the reinforcing cloth 4 is integrated with the pad main body 2 through the slit 30, the slit 30 is formed in that portion of the backing material 3 so as to conform to the cross-sectional shape of the base portion 421 of the reinforcing cloth 4. Since the backing material 3 surrounds the root portion 421 of the reinforcing cloth 4, the root portion 421 is firmly held, and the integration of the reinforcing cloth 4 with the pad body 2 is made more secure. In addition, as described above, since the base portion 421 of the reinforcing cloth 4 is formed by foaming, and the raw material for forming g is impregnated and hardened together with the backing material 3, the reinforcing cloth 4 and the backing material 3 As a result, the reinforcing cloth 4 is completely prevented from coming off from the pad body 2. Stable quality can be maintained.

加えて、パッド本体２の裏面下方へ突出する主部４２の付け根部分４２１の板面領域に、パッド本体２の裏面中央部側から該パッド本体２の裏面外縁２ｅ側へ向けて切込んだカット部分４３が形成されると、該主部４２の先端部分４２２がパッド本体２の裏面外縁２ｅよりも水平外方へ張り出すように、主部４２を折り曲げることが容易になる。図３の製品状態から主部４２を折り曲げて、図４のシートパッド１をシートフレームＦ上に載せ、車両へ組付ける作業が円滑に進む。   In addition, in the plate surface area of the root portion 421 of the main portion 42 projecting downward on the back surface of the pad body 2, a cut is made from the back surface central portion side of the pad body 2 toward the back surface outer edge 2e of the pad body 2 When the portion 43 is formed, it is easy to bend the main portion 42 so that the tip end portion 422 of the main portion 42 protrudes horizontally outward more than the back surface outer edge 2 e of the pad body 2. The main part 42 is bent from the product state of FIG. 3 and the seat pad 1 of FIG. 4 is placed on the seat frame F, and the work of assembling it to the vehicle proceeds smoothly.

また、主部４２が、その付け根部分４２１から先端に向け、該主部４２に近いパッド本体２の裏面外縁側に傾倒するようにして、補強布４がパッド本体２に一体化すると、図１１の状態から図４のシートパッド１をシートフレームＦ上に載せて、車両へ組付ける際、作業者は手を多少あてがうだけ、又は上からそのまま置くだけで、主部４２が水平外方に張り出すようになって、車両にうまく組込むことができ、さらに円滑に作業を進めることができる。
かくのごとく、車両用シートパッド１及びその製造方法は、上述した数々の優れた効果を発揮し極めて有益である。 In addition, when the reinforcing cloth 4 is integrated with the pad main body 2 so that the main part 42 is inclined from the root portion 421 toward the tip and toward the back outer edge side of the pad main body 2 near the main part 42, as shown in FIG. When mounting the seat pad 1 of FIG. 4 on the seat frame F from the state of FIG. 4 and assembling it to a vehicle, the operator only applies a little hand or just puts it from above, the main part 42 is stretched horizontally outward As it comes out, it can be built into a vehicle well and work can proceed more smoothly.
As described above, the vehicle seat pad 1 and the method of manufacturing the same exert the above-mentioned many excellent effects and are extremely useful.

尚、本発明においては前記実施形態に示すものに限られず、目的,用途に応じて本発明の範囲で種々変更できる。シートパッド１、パッド本体２、裏当て材３、補強布４、発泡型５等の形状,大きさ,個数,材質等は用途に合わせて適宜選択できる。実施形態はクッションパッドに適用したが、背もたれ用バックパッドにも適用できる。   In the present invention, the present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention according to the purpose and application. The shape, size, number, material, and the like of the seat pad 1, the pad body 2, the backing material 3, the reinforcing cloth 4, the foaming mold 5 and the like can be appropriately selected according to the application. Although the embodiment is applied to the cushion pad, it is also applicable to the back pad for backrest.

１ シートパッド
２ パッド本体
２ｂ 裏面（パッド本体裏面）
２ｅ パッド本体裏面の外縁（裏面外縁）
３ 裏当て材
３０ スリット
４ 補強布
４１ 基端部
４２ 主部
４２１ 付け根部分
４２２ 先端部分
４３ カット部分
５ 発泡型
７ 上型
７２ 溝穴 1 seat pad 2 pad body 2b back side (pad body back side)
2e Outer edge of back of pad body (back outer edge)
Reference Signs List 3 backing material 30 slit 4 reinforcing cloth 41 base end portion 42 main portion 421 base portion 422 tip portion 43 cut portion 5 foam type 7 upper mold 72 slot

Claims (6)

発泡体からなるパッド本体と、該パッド本体の発泡成形でその裏面に被着一体化されるシート状裏当て材と、を具備する車両用シートパッドにおいて、
前記パッド本体の裏面の外縁寄りに、その発泡成形で、基端部が該裏面よりもパッド本体内へ入り込んで一体化し、主部がパッド本体の裏面から突出した板片状の補強布を、さらに具備し、前記パッド本体の裏面から突出する前記主部の付け根部分に前記裏当て材を配し、且つ該裏当て材のその部位にスリットが形成され、前記補強布が該スリットを貫通して前記パッド本体に一体化されて、該主部が、折り曲げられることにより、その先端部分がパッド本体の裏面外縁よりも外方へ張り出すようにしたことを特徴とする車両用シートパッド。 A vehicle seat pad comprising: a pad body made of foam; and a sheet-like backing material that is integrally attached to the back surface of the pad body by foam molding,
A plate-like reinforcing cloth in which the base end portion is integrated into the pad body and integrated with the back surface by the foam molding near the outer edge of the back surface of the pad body, and the main portion protrudes from the back surface of the pad body, Furthermore, the backing material is disposed at the base of the main part protruding from the back surface of the pad body, and a slit is formed in that part of the backing material, and the reinforcing cloth penetrates the slit. The vehicle seat pad is integrated with the pad body and the main portion is bent so that a tip end portion thereof protrudes outward more than the outer edge of the back surface of the pad body. 前記補強布の板面が該補強布に近い前記パッド本体の裏面外縁に沿って起立配設され、且つ前記パッド本体の裏面から突出する前記主部の付け根部分の板面領域に、パッド本体の裏面中央部側から該パッド本体の裏面外縁側へ向けて切込んだカット部分が形成されてなる請求項１記載の車両用シートパッド。 The plate surface of the reinforcing cloth is disposed upright along the outer periphery of the back surface of the pad body close to the reinforcing cloth, and in the plate surface area of the root portion of the main portion projecting from the back surface of the pad body, 2. The vehicle seat pad according to claim 1 , wherein a cut portion is formed by cutting from the back center portion toward the back outer edge of the pad body . 前記補強布がプレスフェルトからなる請求項１又は２に記載の車両用シートパッド。 The vehicle seat pad according to claim 1, wherein the reinforcing cloth is a press felt . 前記主部が、その付け根部分から先端に向け、該主部に近い前記パッド本体の裏面外縁側へ傾倒するようにして、前記補強布がパッド本体に一体化した請求項１乃至３のいずれか１項に記載の車両用シートパッド。 4. The reinforcing cloth is integrated with the pad main body such that the main part is inclined from the root portion toward the tip and toward the back outer edge side of the pad main body near the main part . A vehicle seat pad according to item 1. パッド本体の裏面外縁寄りに位置する型面部位に、この位置から型面外縁までの距離よりも深さが大の溝穴を上型に形成した発泡型を用い、且つ該溝穴の深さよりも長い板片状の補強布を用い、
型開状態下、上型型面への裏当て材のセットに伴い、前記溝穴に配される該裏当て材の部位にスリットを形成すると共に、該スリットに該補強布を貫通させて、
前記裏当て材のセットと共に、該補強布の基端部を前記溝穴から露出させて、該補強布の主部を溝穴へ挿着保持させ、その後、発泡原料の注入及び型閉じを経て、発泡体からなるパッド本体の裏面側に該裏当て材及び該基端部を一体化させて、該パッド本体を発泡成形し、
前記主部の折り曲げにより、該主部の先端部分がパッド本体の裏面外縁よりも外方へ張り出すようにしたことを特徴とする車両用シートパッドの製造方法。 At the mold surface area located closer to the outer periphery of the back surface of the pad body, a foam mold having a slot with a depth greater than the distance from this position to the outer surface of the mold is used. Using a long piece of reinforcing cloth,
Under the mold open state, along with the setting of the backing material to the upper mold surface, a slit is formed in the portion of the backing material disposed in the slot, and the reinforcing cloth is penetrated through the slit,
With the set of backing materials, the base end of the reinforcing cloth is exposed from the slot, and the main part of the reinforcing cloth is inserted into and held in the slot, and thereafter through injection and mold closing of the foam material. Integrating the backing material and the base end portion on the back surface side of a foam pad body to foam-mold the pad body,
A method of manufacturing a vehicle seat pad, characterized in that the leading end portion of the main portion protrudes outward beyond the outer edge of the back surface of the pad main body by bending the main portion. 前記補強布がプレスフェルトからなる請求項５に記載の車両用シートパッドの製造方法。 The method for manufacturing a vehicle seat pad according to claim 5 , wherein the reinforcing cloth is a press felt .
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