JP6771818B2

JP6771818B2 - Vehicle seat pads and their manufacturing methods

Info

Publication number: JP6771818B2
Application number: JP2016162414A
Authority: JP
Inventors: 佳宏犬飼
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 2016-08-23
Filing date: 2016-08-23
Publication date: 2020-10-21
Anticipated expiration: 2036-08-23
Also published as: JP2018030402A

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 for manufacturing the same.

自動車等の車両用座席シートの座部や背もたれを構成するシートパッドは、従来、快適なクッション性が得られるよう軟質ポリウレタン発泡成形体で造られてきた。ただ近年になり、その一部をビーズ発泡成形体等に担わせて、車両の軽量化に応える動きがある。ビーズ発泡成形体をインサート品にして軟質ポリウレタン発泡成形体を一体発泡成形したシートパッドとする。しかし、シートパッド下面側にビーズ発泡成形体の芯材が露出して、これがシートフレーム等の車体部材と擦れ、時に異音が発生する。そこで、こうしたビーズ発泡成形体を組み込んだシートパッドに対し、異音を抑える発明が提案されている（例えば特許文献１）。 The seat pads that make up the seats and backrests of vehicle seats such as automobiles have conventionally been made of flexible polyurethane foam moldings so as to provide comfortable cushioning. However, in recent years, there has been a movement to respond to the weight reduction of vehicles by carrying a part of them to bead foam molded products and the like. The bead foam molded product is used as an insert product, and the flexible polyurethane foam molded product is integrally foam molded to form a seat pad. However, the core material of the bead foam molded body is exposed on the lower surface side of the seat pad, which rubs against the vehicle body member such as the seat frame, and sometimes an abnormal noise is generated. Therefore, an invention for suppressing abnormal noise has been proposed for a seat pad incorporating such a bead foam molded product (for example, Patent Document 1).

特開２００９−２９７２８５号公報JP-A-2009-297285

しかるに、特許文献１は、「発泡材料よりなるシートパッド本体と、該シートパッド本体の裏面側に配置された発泡成形体とを備えてなるシートパッドにおいて、該発泡成形体を覆うサポータ材を備えたことを特徴とするシートパッド。」の発明内容にとどまる。発泡成形体が特許文献１の明細書や図面に記載のサイド部に埋め込むような小さい物は、これを覆ったサポータ材の接合周縁部での固定によって保持可能であるが、発泡成形体が大きな物になると不具合を招く。車両の軽量化に応えるべく、例えば本願図２のようにシートパッドの下半部を発泡成形体（本発明でいう芯パッド）にすると、特許文献１のサポータ材（本発明でいう裏当て材５）の接合周縁部だけの結合では支障をきたす。発泡成形体を覆うサポータ材を配して、シートパッド本体（本発明でいう表層パッド４）を発泡成形しても、発泡ポリスチレン等からなる発泡成形体とサポータ材との接着力は弱く、図２でいえば芯パッド２の下面中央にある裏当て材５の大部分が垂れ下がる不具合を招く。裏当て材５の周縁部５１での表層パッド４との結合だけでは、芯パッド２と面する裏当て材５の占める面積割合が大きく、且つ両者間の接着もなく、裏当て材５が垂れ下がる。シートパッド１の保管,ハンドリングや車両組付け作業が困難になる。
結局、図９のように、表層パッドｎの下部に軽量化を図る大きなブロック状芯パッドｍを組み込んだ場合は、割布ＳＨと呼ばれる別体の樹脂シートを車体部材ＢＹに被せ、これを介在させて、シートパッドの車体への取付け作業を行い、異音防止を図っている。車両組立てラインで、割布ＳＨの介在作業を強いられ、負担になっている。 However, Patent Document 1 includes "a seat pad including a seat pad main body made of a foam material and a foam molded body arranged on the back surface side of the seat pad main body, and includes a supporter material for covering the foam molded body. It is limited to the content of the invention of "a seat pad characterized by the fact that." A small object such that the foam molded product is embedded in the side portion described in the specification or drawing of Patent Document 1 can be held by fixing the supporter material covering the foam molded product at the joint peripheral portion, but the foam molded product is large. When it comes to things, it causes problems. In order to reduce the weight of the vehicle, for example, when the lower half of the seat pad is made of a foam molded body (core pad in the present invention) as shown in FIG. 2, the supporter material of Patent Document 1 (backing material in the present invention). 5) Joining only the peripheral edge of the joint causes problems. Even if the supporter material covering the foamed molded product is arranged and the seat pad body (surface layer pad 4 in the present invention) is foam-molded, the adhesive force between the foamed molded product made of expanded polystyrene or the like and the supporter material is weak. Speaking of 2, most of the backing material 5 in the center of the lower surface of the core pad 2 hangs down. Only by connecting the backing material 5 to the surface pad 4 at the peripheral edge 51, the area ratio of the backing material 5 facing the core pad 2 is large, and there is no adhesion between the two, and the backing material 5 hangs down. .. Storage, handling and vehicle assembly work of the seat pad 1 become difficult.
After all, as shown in FIG. 9, when a large block-shaped core pad m for weight reduction is incorporated in the lower part of the surface layer pad n, a separate resin sheet called a split cloth SH is put on the vehicle body member BY and interposed. The seat pad is attached to the vehicle body to prevent abnormal noise. On the vehicle assembly line, the intervention work of the split cloth SH is forced, which is a burden.

本発明は、上記問題を解決するもので、軽量化を推進し芯パッドが大きな物になっても、その下面に異音防止用裏当て材を確実に沿わせたシートパッドにして、組立てラインでの作業負担を軽減でき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-mentioned problems, and even if the core pad becomes large by promoting weight reduction, the seat pad is made into a seat pad in which a backing material for preventing abnormal noise is surely placed on the lower surface thereof, and an assembly line is provided. It is an object of the present invention to provide a vehicle seat pad capable of reducing the work load in the vehicle and a method for 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、少なくとも乗員が当接する側の当たり面部分を軟質ポリウレタン発泡体で形成した車両用シートパッドであって、ブロック状に成形されたビーズ発泡成形体にして、その上面側から下面側へ貫通する透孔を設けた芯パッドと、前記透孔の下方側孔口を含めて前記芯パッドの下面を覆う不織布からなる裏当て材と、軟質ポリウレタン発泡体にして、その意匠面側に前記当たり面部分を形成すると共に、前記芯パッドの上面側から前記透孔の下方側孔口を塞ぐ前記裏当て材の部分までの該透孔を埋めて該裏当て材の部分に含浸一体化した軟質ポリウレタン発泡成形部を形成し、且つ前記意匠面側と反対の内面側が前記芯パッドの上面に接合する表層パッドと、を具備し、且つ、前記透孔の下方側孔口を塞ぐ前記裏当て材の部分が前記透孔周りの裏当て材よりも前記芯パッドの上面側に凹んで、凹部が形成され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の車両用シートパッドは、請求項１で、前記透孔が芯パッド下面側の孔径を大きくした拡径部を有し、且つ該拡径部で径が大きくなった前記下方側孔口を塞ぐ前記裏当て材の前記凹部に、前記透孔を埋める前記軟質ポリウレタン発泡成形部に係る拡径部位の軟質ポリウレタン発泡成形部が含浸一体化したことを特徴とする。請求項３の車両用シートパッドは、請求項１又は２で、前記芯パッドの側面に前記表層パッドの側壁部が積層し、該側壁部の下端面を、該側壁部に接する前記芯パッドの側面の下端から段差状に上面側へ後退する段差面にし、且つ前記裏当て材が前記芯パッドを越えて該段差面にまで覆って、前記表層パッドが該段差面上の該裏当て材の周縁部にも含浸一体化したことを特徴とする。
請求項４に記載の発明の要旨は、少なくとも乗員が当接する側の当たり面部分を軟質ポリウレタン発泡体で形成した車両用シートパッドの製造方法であって、疣状凸部を形成した上型キャビティ面に不織布からなる裏当て材をセットすると共に、ブロック状に成形されたビーズ発泡成形体にして、その上面側から下面側へ貫通する透孔を設けた芯パッドを、前記凸部に該透孔を対向させ、下面側が前記裏当て材を介して上型キャビティ面に当接するようにして、該上型キャビティ面にセットし、該セットに伴い、前記凸部が前記透孔に嵌入し、該透孔を塞ぐ前記裏当て材の部分が該透孔周りの裏当て材よりも芯パッドの上面側に凹み、該裏当て材に凹部が形成された後、次いで、下型キャビティ面上に軟質ポリウレタン発泡体用原料を注入すると共に型閉じし、その後、意匠面側に前記当たり面部分を形成すると共に、前記芯パッドの上面側から前記透孔の下方側孔口を塞ぐ前記裏当て材の前記凹部までの前記透孔を埋めて該凹部に含浸一体化した軟質ポリウレタン発泡成形部を形成し、且つ前記意匠面側と反対の内面側が前記芯パッドの上面に接合する軟質ポリウレタン発泡体の表層パッドを発泡成形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５の車両用シートパッドの製造方法は、請求項４で、透孔に芯パッド下面側の孔径を大きくした拡径部を形成して、該拡径部で径が大きくなった前記下方側孔口を塞ぐ前記裏当て材の前記凹部に含浸一体化する前記軟質ポリウレタン発泡成形部に係る拡径部位の軟質ポリウレタン発泡成形部を形成したことを特徴とする。請求項６の車両用シートパッドの製造方法は、請求項４又は５で、型閉じに伴い、インサートされた芯パッドの側面の外側に前記表層パッドの側壁部用キャビティが形成されるようにして、その上型キャビティ面に、前記芯パッドの側面下端セット部位よりも段差状に芯パッド上面側に後退する段差部位を設けて、該段差部位を含めた上型キャビティ面に前記裏当て材をセットす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 is a vehicle seat pad in which at least the contact surface portion on the side where the occupant comes into contact is made of a flexible polyurethane foam, and is molded into a block shape. A backing material made of a bead foam molded product and provided with a through hole penetrating from the upper surface side to the lower surface side, and a non-woven fabric covering the lower surface of the core pad including the lower hole opening of the through hole. , The contact surface portion is formed on the design surface side of the flexible polyurethane foam, and the through hole from the upper surface side of the core pad to the portion of the backing material that closes the lower side hole opening of the through hole. the fill forms a soft polyurethane foam molded part is impregnated integrated with portions of said backing material, and the inner surface side opposite to the design surface side anda surface layer pad bonded to the upper surface of the core pads, and For vehicles, the portion of the backing material that closes the lower side hole opening of the through hole is recessed toward the upper surface side of the core pad with respect to the backing material around the through hole, and a recess is formed . Located on the seat pad. The vehicle seat pad according to claim 2 has a diameter-expanded portion in which the through hole has a larger diameter on the lower surface side of the core pad, and the lower-side hole has a larger diameter at the enlarged diameter portion. The concave portion of the backing material that closes the mouth is impregnated and integrated with the soft polyurethane foam molded portion of the diameter-expanded portion related to the flexible polyurethane foam molded portion that fills the through hole. The vehicle seat pad according to claim 3 is the core pad according to claim 1 or 2, wherein the side wall portion of the surface layer pad is laminated on the side surface of the core pad, and the lower end surface of the side wall portion is in contact with the side wall portion. A stepped surface that recedes from the lower end of the side surface to the upper surface side in a stepped manner, and the backing material covers the stepped surface beyond the core pad, and the surface layer pad is the backing material on the stepped surface. It is characterized by being impregnated and integrated in the peripheral portion.
The gist of the invention according to claim 4 is a method for manufacturing a vehicle seat pad in which at least a contact surface portion on the side where an occupant comes into contact is made of a flexible polyurethane foam, and an upper mold cavity having a ridge-shaped convex portion formed therein. with sets backing material made of a nonwoven fabric on the surface, in the expanded bead moldings molded in a block shape, a core pad having a hole penetrating from the upper surface side to the lower side, the transparent to the protrusion The holes are opposed to each other and set on the upper die cavity surface so that the lower surface side abuts on the upper die cavity surface via the backing material, and the convex portion is fitted into the through hole with the setting. The portion of the backing material that closes the through hole is recessed toward the upper surface side of the core pad with respect to the backing material around the through hole, and after the recess is formed in the backing material, then on the lower cavity surface. The raw material for a flexible polyurethane foam is injected and the mold is closed, and then the contact surface portion is formed on the design surface side, and the backing material that closes the lower hole opening of the through hole from the upper surface side of the core pad. the filling said through hole to the recess to form a flexible polyurethane foam molded part is impregnated integrated with the recess, and the inner surface side opposite to the design surface side of the flexible polyurethane foam to be bonded to the upper surface of the core pads A method for manufacturing a vehicle seat pad, which comprises foam-molding a surface pad. The method for manufacturing a vehicle seat pad according to claim 5 is the method of claim 4, wherein a diameter-expanded portion having a larger hole diameter on the lower surface side of the core pad is formed in the through hole, and the diameter of the enlarged portion is increased. It is characterized in that a soft polyurethane foam molded portion having a diameter-expanded portion related to the flexible polyurethane foam molded portion that is impregnated and integrated into the recess of the backing material that closes the side hole opening is formed. The method for manufacturing a vehicle seat pad according to claim 6 is the method according to claim 4 or 5, wherein the side wall cavity of the surface pad is formed on the outside of the side surface of the inserted core pad as the mold is closed. The upper die cavity surface is provided with a stepped portion that recedes toward the upper surface side of the core pad in a stepped shape from the side lower end setting portion of the core pad, and the backing material is applied to the upper die cavity surface including the stepped portion. It is characterized by being set.

本発明の車両用シートパッド及びその製造方法は、芯パッドに透孔を設けると共に、芯パッドの上面側から透孔の下方側孔口を塞ぐ裏当て材の部分までの該透孔を埋めて該裏当て材の部分に含浸一体化した軟質ポリウレタン発泡成形部を形成した表層パッドとすることで、裏当て材は、その周縁部に限らず、透孔を埋める軟質ポリウレタン発泡成形部の下方側孔口に固定一体化するので、芯パッド裏面から裏当て材が垂れ下がることがなくなり、芯パッド下面に裏当て材が沿う取扱い易い裏当て材付きシートパッドができ、組立てラインでの作業負担の軽減のみならず、保管,ハンドリング等にも優れた効果を発揮する。 In the vehicle seat pad of the present invention and the method for manufacturing the same, a through hole is provided in the core pad, and the through hole is filled from the upper surface side of the core pad to the portion of the backing material that closes the hole opening on the lower side of the through hole. By forming a surface layer pad in which a flexible polyurethane foam molded portion impregnated and integrated with the backing material portion is formed, the backing material is not limited to the peripheral portion thereof, but is the lower side of the flexible polyurethane foam molded portion that fills the through holes. Since it is fixedly integrated with the hole opening, the backing material does not hang down from the back surface of the core pad, and a seat pad with a backing material that is easy to handle along the bottom surface of the core pad can be created, reducing the work load on the assembly line. Not only that, it has excellent effects on storage and handling.

本発明のシートパッドの一形態で、その斜視図である。It is one form of the seat pad of this invention, and is the perspective view. 図１のII-II線矢視図である。FIG. 2 is a view taken along the line II-II of FIG. 図２の部分拡大図である。It is a partially enlarged view of FIG. 型開状態の上型に裏当て材と芯パッドをセットする説明断面図である。It is explanatory cross-sectional view which sets the backing material and the core pad in the upper mold in the mold open state. 型開状態の下型に発泡原料を注入する断面図である。It is sectional drawing which injects the foaming raw material into the lower mold in the mold open state. 型閉じした断面図である。It is a cross-sectional view with a mold closed. 裏当て材及び芯パッドと一体の表層パッドを発泡成形した断面図である。It is sectional drawing which foam-molded the surface layer pad integrated with a backing material and a core pad. 脱型後のシートパッドの部分拡大断面図である。It is a partially enlarged sectional view of the seat pad after demolding. 従来技術の説明断面図である。It is explanatory sectional view of the prior art.

以下、本発明に係る車両用シートパッド（以下、単に「シートパッド」ともいう。）及びその製造方法について詳述する。図１〜図８は本発明のシートパッド及びその製造方法の一形態で、図１はシートパッドの斜視図、図２は図１のII-II線矢視図、図３は図２の部分拡大図、図４は型開状態の上型に裏当て材と芯パッドをセットする説明断面図、図５は型開状態の下型に発泡原料を注入する断面図、図６は型閉じした断面図、図７は裏当て材及び芯パッドと一体の表層パッドを発泡成形した断面図、図８は脱型後のシートパッドの部分拡大断面図を示す。
各図は図面を判り易くするため発明要部の透孔２３,軟質ポリウレタン発泡成形部４３,裏当て材５,疣状凸部９３を強調図示し、また本発明と直接関係しない部分を省略する。芯パッド２及び裏当て材５は断面表示のハッチングを省く。 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 8 are one form of the seat pad of the present invention and a method for manufacturing the same. FIG. 1 is a perspective view of the seat pad, FIG. 2 is a sectional view taken along line II-II of FIG. 1, and FIG. 3 is a portion of FIG. An enlarged view, FIG. 4 is an explanatory cross-sectional view in which the backing material and the core pad are set in the upper mold in the mold open state, FIG. 5 is a cross-sectional view in which the foamed raw material is injected into the lower mold in the mold open state, and FIG. 6 is the mold closed. A cross-sectional view, FIG. 7 is a cross-sectional view in which a surface pad integrated with a backing material and a core pad is foam-molded, and FIG. 8 is a partially enlarged cross-sectional view of the seat pad after demolding.
In each drawing, the through hole 23, the flexible polyurethane foam molded portion 43, the backing material 5, and the wart-shaped convex portion 93 of the main part of the invention are highlighted in order to make the drawing easier to understand, and the parts not directly related to the present invention are omitted. .. The core pad 2 and the backing material 5 omit the hatching of the cross-sectional display.

（１）シートパッドの製造方法
車両用シートパッドの製造方法は、少なくとも乗員が当接する側の当たり面部分４１を軟質ポリウレタン発泡成形体で形成し、表層パッド４の発泡成形で、該表層パッド４と裏当て材５とを一体化させ、裏当て材５を芯パッド裏面２ｂに沿わせる裏当て材５付きシートパッドの製法である(図７)。シートパッド１は、車両用座席シートの座部や背もたれに使用される。ここでは、図１に示す車両後部座席の座部用クッションパッドに適用する。図２の車両設置状態にあるクッションパッド１は紙面の右方が車両前方、左方が車両後方、紙面上方が上方、紙面下方が下方である。本発明でいう上方、下方もこれにならう。本発明でいう芯パッド２の上面２ａ側,下面２ｂ側も、図２の車両設置状態に在るクッションパッド(シートパッド)１に組み込まれている芯パッド２で、その上面側,下面側を指す。また本発明のシートパッドはバックパッドにも適用でき、斯かる場合の本発明でいう上方,上面側は、着座乗員と接する側の方向,着座乗員と接する面側になり、下方,下面側はその反対方向,その反対面側になる。
表層パッド４の発泡成形に先立ち、芯パッド２と裏当て材５と発泡成形型７が用意される。 (1) Manufacturing method of seat pad In the manufacturing method of the seat pad for a vehicle, at least the contact surface portion 41 on the side where the occupant comes into contact is formed of a flexible polyurethane foam molded body, and the surface layer pad 4 is foam-molded. This is a method for manufacturing a seat pad with a backing material 5 in which the backing material 5 is integrated with the backing material 5 and the backing material 5 is aligned with the back surface 2b of the core pad (FIG. 7). The seat pad 1 is used for a seat portion and a backrest of a vehicle seat. Here, it is applied to the cushion pad for the seat of the rear seat of the vehicle shown in FIG. In the cushion pad 1 in the vehicle-installed state of FIG. 2, the right side of the paper is the front of the vehicle, the left is the rear of the vehicle, the upper part of the paper is the upper part, and the lower part of the paper is the lower part. The upper and lower parts of the present invention follow this. The upper surface 2a side and the lower surface 2b side of the core pad 2 in the present invention are also the core pads 2 incorporated in the cushion pad (seat pad) 1 in the vehicle installed state of FIG. Point to. Further, the seat pad of the present invention can also be applied to a back pad, and in such a case, the upper side and the upper surface side in the present invention are the direction of the side in contact with the seated occupant and the surface side in contact with the seated occupant. In the opposite direction, on the opposite side.
Prior to foam molding of the surface pad 4, a core pad 2, a backing material 5, and a foam molding mold 7 are prepared.

芯パッド２は、図２のようにブロック状に成形されたビーズ発泡成形体で、車両後部座席用シートパッド１の略下半部占める大きなサイズになっている。芯パッド２のビーズ発泡成形体にはその上面２ａ側から下面２ｂ側へ貫通する透孔２３が設けられる。図２の芯パッド２は透孔２３を三箇所形成する。車両前方側に在る透孔２３は芯パッド下面２ｂ側の孔径を大きくした拡径部２３１を形成している(図８)。 The core pad 2 is a bead foam molded body molded into a block shape as shown in FIG. 2, and has a large size that occupies substantially the lower half of the seat pad 1 for the rear seat of the vehicle. The bead foam molded body of the core pad 2 is provided with a through hole 23 penetrating from the upper surface 2a side to the lower surface 2b side. The core pad 2 of FIG. 2 forms three through holes 23. The through hole 23 on the front side of the vehicle forms a diameter-expanded portion 231 having a larger hole diameter on the lower surface 2b side of the core pad (FIG. 8).

芯パッド２は、見掛け密度が前記軟質ポリウレタン発泡成形体よりも小のビーズ発泡成形体である。表層パッド４を形成する軟質ポリウレタン発泡成形体の見掛け密度よりも見掛け密度が小のビーズ発泡成形体で構成し、シートパッド１の裏面側に配される芯部材である。芯パッド２と表層パッド４との密度比較は、発泡前の素材の密度でなく、発泡後の見掛け密度で比較する。
ここで、本発明でいう「ビーズ発泡成形体」とは、いわゆるビーズ発泡法(特許第4855138号,特開2015-101620号,特開2013-22911号,特開2011-105879号等)によって得られた発泡成形体で、ペレットに発泡剤を含浸したビーズを予備発泡成形し、その後の型内発泡成形によって成形されている発泡成形体をいう。ビーズ発泡法は単にビーズ法もいう。芯パッド２のビーズ発泡成形体は、見掛け密度が表層パッド４を形成する軟質ポリウレタン発泡成形体の見掛け密度よりも小さければ充足するが、発泡ポリプロピレン、発泡スチロール、発泡ポリエチレン、又はこれらの一つを少なくとも含む成形体であるのがより好ましい。例えばビーズ法発泡スチロールの発泡スチロールの成形体は、気泡が内部に密閉されたビーズ発泡成形体となっており、且つ体積の大部分が気体で軽量にして、その見掛け密度を軟質ポリウレタン発泡成形体の見掛け密度よりも小さくできる。 The core pad 2 is a bead foam molded product having an apparent density smaller than that of the flexible polyurethane foam molded product. It is a core member composed of a bead foam molded body having an apparent density smaller than the apparent density of the flexible polyurethane foam molded body forming the surface pad 4, and is arranged on the back surface side of the seat pad 1. The density of the core pad 2 and the surface pad 4 is compared not by the density of the material before foaming but by the apparent density after foaming.
Here, the "bead foam molded article" referred to in the present invention is obtained by the so-called bead foaming method (Patent No. 4855138, JP 2015-101620, JP 2013-22911, JP 2011-105879, etc.). This is a foam molded product obtained by pre-foam molding beads impregnated with a foaming agent in pellets and then performing in-mold foam molding. The bead foaming method is also simply referred to as the bead method. The bead foam molded product of the core pad 2 is sufficient if the apparent density is smaller than the apparent density of the flexible polyurethane foam molded product forming the surface pad 4, but at least one of foamed polypropylene, expanded polystyrene, foamed polyethylene, or one of them is satisfied. It is more preferable that the molded product contains. For example, the styrofoam molded product of the bead method styrofoam is a beaded styrofoam molded product in which air bubbles are sealed inside, and most of the volume is made lightweight by gas, and the apparent density is the appearance of the flexible polyurethane foam molded product. Can be less than density.

裏当て材５は、透孔２３の下方側孔口２３ｂを含めて前記芯パッド２の下面２ｂを覆う不織布からなるシート状体である。芯パッド下面２ｂよりも若干大き目の裏当て材５が作製される。裏当て材５はシートパッド１の下面に現れる芯パッド下面２ｂを覆い尽くし、芯パッド２の外側に配される裏当て材周縁部５１が、表層パッド４の発泡成形で、該表層パッド４に一体化する大きさになっている。 The backing material 5 is a sheet-like body made of a non-woven fabric that covers the lower surface 2b of the core pad 2 including the lower hole opening 23b of the through hole 23. A backing material 5 slightly larger than the core pad lower surface 2b is produced. The backing material 5 completely covers the core pad lower surface 2b appearing on the lower surface of the seat pad 1, and the backing material peripheral edge portion 51 arranged on the outside of the core pad 2 is formed by foam molding of the surface layer pad 4 to form the surface pad 4. It is sized to be integrated.

発泡成形型７は、図５,図６のごとくの分割型で、下型８と上型９は開閉可能に接続されている。図６のごとく型閉じすると、全体が椀状にへこんで着座乗員の当たり面部分４１を形成する下型キャビティ面８１と、全体がほぼ平坦な芯パッド２の下面２ｂに合わせた上型キャビティ面９１とで、シートパッド１のキャビティＣをつくる。本実施形態は、裏当て材５を介して芯パッド２をセットする上型キャビティ面９１に疣状凸部９３を形成する。疣状凸部９３は、芯パッド２の上型９へのセットで、透孔２３と対向箇所に設ける。また、型閉じに伴い、インサートされた芯パッド２の側面２５の外側に表層パッド４の側壁部用キャビティＣ１が形成されるようにする。且つ該側壁部用キャビティＣ１を形成する上型キャビティ面９１に、芯パッド２の側面下端セット部位９１０よりも段差状に芯パッド上面２ａ側(図４,図５の紙面下方側)に後退する段差部位９１１を設ける。上型キャビティ面９１への前記裏当て材５のセットで、裏当て材周縁部５１がセットされる箇所に該段差部位９１１が設けられる。尚、図４〜図７の発泡成形型７は、車両設置状態にある図２のシートパッド１と上下が逆の姿態で、芯パッド２と裏当て材５と一体の表層パッド４を発泡成形するシートパッド製造型になっている。これに伴い、発泡成形型７にセットする芯パッド２も、車両設置状態にある図２のシートパッド１に組み込まれた芯パッド２と上下が逆になる。 The foam molding mold 7 is a split mold as shown in FIGS. 5 and 6, and the lower mold 8 and the upper mold 9 are connected so as to be openable and closable. When the mold is closed as shown in FIG. 6, the lower cavity surface 81, which is entirely dented in a bowl shape to form the contact surface portion 41 of the seated occupant, and the upper cavity surface, which is aligned with the lower surface 2b of the core pad 2 which is almost flat as a whole. With 91, the cavity C of the seat pad 1 is made. In the present embodiment, the wart-shaped convex portion 93 is formed on the upper die cavity surface 91 on which the core pad 2 is set via the backing material 5. The wart-shaped convex portion 93 is set on the upper mold 9 of the core pad 2 and is provided at a position facing the through hole 23. Further, as the mold is closed, the side wall cavity C1 of the surface pad 4 is formed on the outside of the side surface 25 of the inserted core pad 2. Further, the upper cavity surface 91 forming the side wall cavity C1 recedes toward the core pad upper surface 2a side (lower side of the paper surface in FIGS. 4 and 5) in a stepped manner from the side lower end setting portion 910 of the core pad 2. A step portion 911 is provided. In the set of the backing material 5 on the upper die cavity surface 91, the step portion 911 is provided at a position where the backing material peripheral edge portion 51 is set. In the foam molding molds 7 of FIGS. 4 to 7, the surface pad 4 integrated with the core pad 2 and the backing material 5 is foam-molded in a state in which the seat pad 1 of FIG. 2 in the vehicle installed state is turned upside down. It is a seat pad manufacturing type. Along with this, the core pad 2 set in the foam molding mold 7 is also turned upside down from the core pad 2 incorporated in the seat pad 1 of FIG. 2 in the vehicle installed state.

前記発泡成形型７と芯パッド２と裏当て材５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、発泡成形型７を型開状態とする。この型開状態下、裏当て材５と芯パッド２とを上型９にセットする(図４)。上型キャビティ面９１に不織布からなる裏当て材５をセットする。芯パッド下面２ｂよりも大きくした裏当て材５の周縁部５１を前記段差部位９１１に配するようにして、上型キャビティ面９１に裏当て材５をセットする。続いて、ブロック状に成形されたビーズ発泡成形体で、その上面２ａ側から下面２ｂ側へ透孔２３が貫通形成された芯パッド２を、該上型キャビティ面９１にセットする。疣状凸部９３に透孔２３を対向させた芯パッド２を、下面２ｂ側が裏当て材５を介して上型キャビティ面９１に当接するようにして、上型キャビティ面９１にセットする。芯パッド２のセットに伴い、上型９に設けた疣状凸部９３が透孔２３に嵌入し、透孔２３を塞ぐ裏当て材の部分５０ａが該透孔２３周りの裏当て材５よりも芯パッド２の上面２ａ側に凹み、該裏当て材５に凹部５０が形成される(図５)。 The seat pad 1 is manufactured, for example, as follows by using the foam molding mold 7, the core pad 2, and the backing material 5.
First, the foam molding die 7 is opened. Under this mold open state, the backing material 5 and the core pad 2 are set in the upper mold 9 (FIG. 4). A backing material 5 made of a non-woven fabric is set on the upper cavity surface 91. The backing material 5 is set on the upper die cavity surface 91 so that the peripheral edge portion 51 of the backing material 5 larger than the lower surface 2b of the core pad is arranged on the step portion 911. Subsequently, a core pad 2 having a through hole 23 formed through the upper surface 2a side to the lower surface 2b side of the bead foam molded body formed into a block shape is set on the upper die cavity surface 91. The core pad 2 having the through hole 23 facing the wart-shaped convex portion 93 is set on the upper die cavity surface 91 so that the lower surface 2b side abuts on the upper die cavity surface 91 via the backing material 5. Along with the setting of the core pad 2, the wart-shaped convex portion 93 provided on the upper mold 9 is fitted into the through hole 23, and the portion 50a of the backing material that closes the through hole 23 is formed from the backing material 5 around the through hole 23. The wart pad 2 is recessed on the upper surface 2a side, and the recess 50 is formed in the backing material 5 (FIG. 5).

次に、下型キャビティ面８１上に軟質ポリウレタン発泡体用原料を注入すると共に型閉じする。椀状にへこむ下型キャビティ面８１上に、注入ノズルＮＬ等を使用して表層パッド４用発泡原料ｇ（軟質ポリウレタン発泡成形体用原料）を所定量注入する（図５）。続いて、上型９を作動させ型閉じする（図６）。上型９と下型８との型閉じで、芯パッド２がインサートセットされたシートパッド１用キャビティＣができる。尚、本実施形態は発泡原料ｇの注入後に型閉じしたが、型閉じした後、発泡原料ｇを注入することもできる。 Next, the raw material for the flexible polyurethane foam is injected onto the lower mold cavity surface 81 and the mold is closed. A predetermined amount of the foaming raw material g for the surface pad 4 (raw material for the flexible polyurethane foam molded product) is injected onto the lower cavity surface 81 that is dented in a bowl shape using an injection nozzle NL or the like (FIG. 5). Subsequently, the upper mold 9 is operated to close the mold (FIG. 6). By closing the upper mold 9 and the lower mold 8, the cavity C for the seat pad 1 in which the core pad 2 is insert-set is formed. In this embodiment, the mold is closed after the foaming raw material g is injected, but the foaming raw material g can be injected after the mold is closed.

型閉じ後、主工程の表層パッド４の発泡成形に移る。意匠面４ａ側に着座乗員の当たり面部分４１(ここでは「座面部分」)を有する、軟質ポリウレタン発泡成形体からなる表層パッド４を発泡成形する。
ここで、芯パッド２に透孔２３を設け、且つ該透孔２３の下方側孔口２３ｂを裏当て材５で塞いでいると、型閉じ後の発泡成形で、発泡原料ｇは、乗員が当接する側の当たり面部分４１を有する表層パッド本体用キャビティを埋めるように上昇する過程で、透孔２３内へと進出する。表層パッド４の発泡成形過程で、発泡原料ｇが当たり面部分４１を形成すると共に該透孔２３内を埋め、下方側孔口２３ｂの裏当て材の部分５０ａに含浸一体化する軟質ポリウレタン発泡成形部４３を形成して、芯パッド上面２ａに内面４ｂ側が接合した表層パッド４を発泡成形する(図７)。発泡原料ｇで当たり面部分４１を成形し、且つ透孔２３を埋めて三次元網目構造の不織布からなる裏当て材の部分５０ａに発泡原料ｇが含浸一体化して、芯パッド下面２ｂ以外の芯パッド２の上面２ａ及び側面２５を覆う図２,図３ごとくの表層パッド４を発泡成形する。さらに、透孔２３の下方側孔口２３ｂ周りに拡径部２３１が設けられていると(図８)、透孔２３を埋める軟質ポリウレタン発泡成形部４３で、拡径部位の軟質ポリウレタン発泡成形部４３１を形成するので、発泡原料ｇが含浸一体化する裏当て材の部分５０ａが広がり、表層パッド４への裏当て材５の更なる一体強化が図られたシートパッド１を造る。さらにいえば、透孔２３を埋めた軟質ポリウレタン発泡成形部４３や、拡径部位の軟質ポリウレタン発泡成形部４３１がアンカー効果を発揮し、芯パッド２と表層パッド４との一体化にも役立つシートパッド１を造ることになる（詳細後述）。 After closing the mold, the process proceeds to foam molding of the surface pad 4 in the main process. A surface pad 4 made of a flexible polyurethane foam molded product having a seated occupant contact surface portion 41 (here, a “seat surface portion”) on the design surface 4a side is foam-molded.
Here, when the core pad 2 is provided with the through hole 23 and the lower hole opening 23b of the through hole 23 is closed with the backing material 5, the foaming raw material g is produced by the occupant in the foam molding after the mold is closed. In the process of ascending so as to fill the cavity for the surface layer pad main body having the contact surface portion 41 on the abutting side, it advances into the through hole 23. In the foam molding process of the surface pad 4, the foamed raw material g forms the contact surface portion 41, fills the inside of the through hole 23, and impregnates and integrates the backing material portion 50a of the lower hole opening 23b. A surface pad 4 having an inner surface 4b side bonded to an upper surface 2a of the core pad is foam-molded by forming the portion 43 (FIG. 7). The contact surface portion 41 is molded with the foamed raw material g, and the foamed raw material g is impregnated and integrated into the portion 50a of the backing material made of a non-woven fabric having a three-dimensional network structure by filling the through holes 23, and the core other than the core pad lower surface 2b is integrated. The surface pad 4 as shown in FIGS. 2 and 3 covering the upper surface 2a and the side surface 25 of the pad 2 is foam-molded. Further, when the diameter-expanded portion 231 is provided around the lower hole opening 23b of the through-hole 23 (FIG. 8), the flexible polyurethane foam-molded portion 43 that fills the through-hole 23 is the soft polyurethane foam-molded portion of the enlarged-diameter portion. Since 431 is formed, the portion 50a of the backing material impregnated and integrated with the foaming raw material g is expanded, and the seat pad 1 is manufactured in which the backing material 5 is further integrally strengthened to the surface pad 4. Furthermore, the flexible polyurethane foam molded portion 43 in which the through hole 23 is filled and the flexible polyurethane foam molded portion 431 in the enlarged diameter portion exert an anchor effect, and a sheet useful for integrating the core pad 2 and the surface layer pad 4. Pad 1 will be built (details will be described later).

本実施形態は、上型９の疣状凸部９３によって、下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａに凹部５０が形成されており、この凹んだ凹部５０に発泡原料ｇが含浸して、裏当て材５が表層パッド４と一体化する。さらに拡径部２３１を設けた下方側孔口２３ｂ周りの透孔２３を埋める軟質ポリウレタン発泡成形部４３では、図８のごとく拡径部位の軟質ポリウレタン発泡成形部４３１を形成し、拡径部２３１で径が大きくなった下方側孔口２３ｂを塞ぐ裏当て材５の凹部５０の形成面積も大きくなり、裏当て材５と表層パッド４との結合力も一段と高まっている。また、段差部位９１１の載った裏当て材５の周縁部５１が、芯パッド２の側面下端２５１を越え、表層パッド４に係る側壁部４５の下端面たる段差面４５１に直かに結合し一体化する。 In the present embodiment, the wart-shaped convex portion 93 of the upper mold 9 forms a recess 50 in the portion 50a of the backing material that closes the lower hole opening 23b, and the recessed recess 50 is impregnated with the foaming raw material g. The backing material 5 is integrated with the surface pad 4. Further, in the flexible polyurethane foam molding portion 43 that fills the through hole 23 around the lower hole opening 23b provided with the diameter expansion portion 231, the soft polyurethane foam molding portion 431 of the diameter expansion portion is formed as shown in FIG. 8, and the diameter expansion portion 231 is formed. The forming area of the recess 50 of the backing material 5 that closes the lower hole opening 23b whose diameter has been increased is also increased, and the bonding force between the backing material 5 and the surface pad 4 is further increased. Further, the peripheral edge portion 51 of the backing material 5 on which the stepped portion 911 is placed exceeds the lower end surface 251 of the side surface of the core pad 2 and is directly connected to and integrated with the stepped surface 451 which is the lower end surface of the side wall portion 45 related to the surface layer pad 4. To become.

型閉じ状態を所定時間維持し(図６)、発泡原料ｇが、当たり面部分４１を形成すると共に、透孔２３を埋める軟質ポリウレタン発泡成形部４３を形成して、下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａに含浸一体化する。また、発泡原料ｇが芯パッド側面２５を覆う側壁部４５を形成し、且つ段差部位９１１に配した裏当て材周縁部５１に含浸一体化して、意匠面４ａ側と反対の内面４ｂ側が芯パッド上面２ａに接合した表層パッド４を発泡成形する(図７)。
表層パッド４の発泡成形を終え、脱型すれば、裏当て材５と表層パッド４が一体となり、裏当て材５が芯パッド下面２ｂに寄り添う所望のシートパッド１が得られる(図１〜図３、図８)。さらに、透孔２３を埋める軟質ポリウレタン発泡成形部４３の形成で、芯パッド２も表層パッド４に一体化する良好なシートパッド１が得られる。
図中、符号８４は吊溝４９の横溝形成部、符号８９,符号９９は型合せ面を示す。 The mold closed state is maintained for a predetermined time (FIG. 6), and the foaming raw material g forms the contact surface portion 41 and the flexible polyurethane foam molding portion 43 that fills the through hole 23 to close the lower hole opening 23b. It is impregnated and integrated into the backing material portion 50a. Further, the foamed raw material g forms a side wall portion 45 that covers the side surface 25 of the core pad, and is impregnated and integrated with the peripheral portion 51 of the backing material arranged at the step portion 911, so that the inner surface 4b side opposite to the design surface 4a side is the core pad. The surface pad 4 joined to the upper surface 2a is foam-molded (FIG. 7).
When the foam molding of the surface pad 4 is completed and the mold is removed, the backing material 5 and the surface pad 4 are integrated, and the desired seat pad 1 in which the backing material 5 is close to the core pad lower surface 2b can be obtained (FIGS. 1 to 1). 3, Fig. 8). Further, by forming the flexible polyurethane foam molded portion 43 that fills the through hole 23, a good seat pad 1 in which the core pad 2 is also integrated with the surface layer pad 4 can be obtained.
In the figure, reference numeral 84 indicates a lateral groove forming portion of the suspension groove 49, and reference numerals 89 and 99 indicate a type matching surface.

（２）シートパッド
図１〜図８の上記製造方法等で得られるシートパッド１（ここでは「クッションパッド」）は、少なくとも乗員が当接する側の当たり面部分４１を軟質ポリウレタン発泡体で形成して、芯パッド２と裏当て材５と表層パッド４とを具備するシートパッドである。 (2) Seat Pad In the seat pad 1 (here, "cushion pad") obtained by the above-mentioned manufacturing methods shown in FIGS. 1 to 8, at least the contact surface portion 41 on the side where the occupant comes into contact is formed of a soft polyurethane foam. This is a seat pad including a core pad 2, a backing material 5, and a surface pad 4.

芯パッド２は、ブロック状に成形されたビーズ発泡成形体にして、その上面２ａ側から下面２ｂ側へ貫通する透孔２３が設けられる。さらに複数ある透孔２３のいくつかは下面２ｂ側に、透孔２３に係る上方側孔口２３ａのメイン孔径よりも孔径が大きな拡径部２３１が設けられた芯パッド２とする。拡径部２３１は図１〜図８のような柱状凹みとしたが、芯パッド下面２ｂ側から上面２ａ側に向けてテーパ状に孔径が狭まるすり鉢状凹みにしてもよい。
芯パッド２は、既述のごとくビーズ発泡成形体のうちでも、発泡ポリプロピレン、発泡スチロール、発泡ポリエチレン、又はこれらの一つを少なくとも含む成形体であるのがより好ましい。 The core pad 2 is a bead foam molded body molded into a block shape, and is provided with a through hole 23 penetrating from the upper surface 2a side to the lower surface 2b side. Further, some of the plurality of through holes 23 are core pads 2 provided with an enlarged diameter portion 231 having a hole diameter larger than the main hole diameter of the upper hole opening 23a related to the through hole 23 on the lower surface 2b side. The enlarged diameter portion 231 has a columnar recess as shown in FIGS. 1 to 8, but may be a mortar-shaped recess in which the hole diameter is tapered from the lower surface 2b side of the core pad to the upper surface 2a side.
As described above, the core pad 2 is more preferably a molded product containing at least one of foamed polypropylene, expanded polystyrene, foamed polyethylene, or one of them among the bead foamed molded products.

裏当て材５は、透孔２３の下方側孔口２３ｂを含めて芯パッド２の下面２ｂを覆う不織布からなるシート材である。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、シート状にした不織布を用いた裏当て材５とする。不織布は異音対策用素材として優れる。また三次元網目構造の不織布を用いることによって、発泡原料ｇの裏当て材５への含浸一体化が円滑に進む。
裏当て材５は、シートパッド１の下面に露出する芯パッド下面２ｂを覆い、さらに表層パッド４の発泡成形で、芯パッド２の外側の表層パッド４に係る側壁部４５の下端面４５１に載置,結合できる周縁部５１を備える。 The backing material 5 is a sheet material made of a non-woven fabric that covers the lower surface 2b of the core pad 2 including the lower hole opening 23b of the through hole 23. The backing material 5 is made of a non-woven fabric in the form of a sheet by fixing or entwining the fibers mechanically, chemically, or thermally without weaving. Non-woven fabric is an excellent material for measures against abnormal noise. Further, by using the non-woven fabric having a three-dimensional network structure, the impregnation integration of the foamed raw material g into the backing material 5 proceeds smoothly.
The backing material 5 covers the lower surface 2b of the core pad exposed on the lower surface of the seat pad 1, and is further foam-molded on the surface pad 4 so as to be mounted on the lower end surface 451 of the side wall portion 45 related to the outer surface pad 4 of the core pad 2. A peripheral edge portion 51 that can be placed and connected is provided.

表層パッド４は、軟質ポリウレタン発泡体にして、その意匠面４ａ側に当たり面部分４１が形成されると共に、芯パッド２の上面２ａ側から透孔２３の下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａまでの該透孔２３を埋めて該裏当て材の部分５０ａに含浸一体化した軟質ポリウレタン発泡成形部４３が形成される。且つ意匠面４ａ側の当たり面部分４１に加え、その反対の内面４ｂ側を芯パッド２の上面２ａに接合させた軟質ポリウレタン発泡成形主要部が形成された発泡成形体になっている。 The surface pad 4 is made of a flexible polyurethane foam, and a contact surface portion 41 is formed on the design surface 4a side thereof, and a backing material that closes the lower hole opening 23b of the through hole 23 from the upper surface 2a side of the core pad 2. A flexible polyurethane foam molded portion 43 is formed by filling the through holes 23 up to the portion 50a and impregnating and integrating the portion 50a of the backing material. In addition to the contact surface portion 41 on the design surface 4a side, the foam molded body is formed with a flexible polyurethane foam molding main portion in which the opposite inner surface 4b side is joined to the upper surface 2a of the core pad 2.

さらに、本実施形態は図３,図８のように透孔２３の下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａが透孔２３周りの裏当て材５よりも芯パッド２の上面２ａ側に凹んで、凹部５０が形成されたシートパッド１としている。凹部５０を形成し、表層パッド４の発泡成形で、透孔２３の下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａに発泡原料ｇを含浸一体化させることによって、該凹部５０の箇所で表層パッド４と裏当て材５とが結合する。凹部５０を形成する透孔２３に関しては、図８のごとく透孔２３の下面２ｂ側に孔径を広げた拡径部２３１を備えると、より好ましくなる。該拡径部２３１に入り込む凹部５０を形成すると、表層パッド４と結合する裏当て材５の凹部５０の面積を増やすことができ、表層パッド４(透孔２３を埋める軟質ポリウレタン発泡成形部４３)と裏当て材５との結合力が一層高まるからである。尚、拡径部２３１にはその一部を埋める軟質ポリウレタン発泡成形部４３１が充填形成される(図８)。該軟質ポリウレタン発泡成形部４３１の天面が凹部５０の底面になる。 Further, in the present embodiment, as shown in FIGS. 3 and 8, the portion 50a of the backing material that closes the lower hole opening 23b of the through hole 23 is closer to the upper surface 2a of the core pad 2 than the backing material 5 around the through hole 23. The seat pad 1 is recessed and has a recess 50 formed therein. The recess 50 is formed, and by foam molding the surface pad 4, the surface layer is formed at the recess 50 by impregnating and integrating the foaming raw material g into the portion 50a of the backing material that closes the lower hole 23b of the through hole 23. The pad 4 and the backing material 5 are combined. With respect to the through hole 23 forming the recess 50, it is more preferable to provide a diameter-expanded portion 231 having an enlarged hole diameter on the lower surface 2b side of the through hole 23 as shown in FIG. By forming the recess 50 that penetrates into the enlarged diameter portion 231, the area of the recess 50 of the backing material 5 that is bonded to the surface pad 4 can be increased, and the surface pad 4 (the flexible polyurethane foam molded portion 43 that fills the through hole 23). This is because the bonding force between the backing material 5 and the backing material 5 is further enhanced. The diameter-expanded portion 231 is filled with a flexible polyurethane foam-molded portion 431 that fills a part thereof (FIG. 8). The top surface of the flexible polyurethane foam molded portion 431 becomes the bottom surface of the recess 50.

また、本シートパッド１は、芯パッド２の側面２５に表層パッド４の側壁部４５が積層し、該側壁部４５の下端面を、該側壁部４５に接する芯パッド２の側面の下端２５１から段差状に上面２ａ側へ後退する段差面４５１にしている。そして、裏当て材５が芯パッド２を越えて該段差面４５１にまで覆って、表層パッド側壁部４５がその段差面４５１で裏当て材５の周縁部５１に含浸一体化する所望のシートパッド１に仕上がっている。斯かるシートパッド１に表皮ＨＹを被せれば、車両用後部座席の座部側シートパッド１が完成する。
符号４Ａはメイン部、符号４Ｂはサイド部、符号４Ｃは補助席部、符号４Ｄは斜面、符号４Ｅはバックレストとの合わせ部を示す。他の構成は（１）シートパッドの製造方法で述べた構成と同様で、その説明を省く。（１）で述べた符号と同一符号は同一又は相当部分を示す。 Further, in the present sheet pad 1, the side wall portion 45 of the surface layer pad 4 is laminated on the side surface 25 of the core pad 2, and the lower end surface of the side wall portion 45 is formed from the lower end surface 251 of the side surface of the core pad 2 in contact with the side wall portion 45. A stepped surface 451 that recedes toward the upper surface 2a side in a stepped shape is provided. Then, the backing material 5 covers the stepped surface 451 beyond the core pad 2, and the surface pad side wall portion 45 is impregnated and integrated with the peripheral edge portion 51 of the backing material 5 at the stepped surface 451. It is finished in 1. By covering the seat pad 1 with the skin HY, the seat pad 1 on the seat side of the rear seat for the vehicle is completed.
Reference numeral 4A is a main portion, reference numeral 4B is a side portion, reference numeral 4C is an auxiliary seat portion, reference numeral 4D is a slope, and reference numeral 4E is a matching portion with a backrest. Other configurations are the same as those described in (1) Method for manufacturing seat pad, and the description thereof will be omitted. The same code as the code described in (1) indicates the same or equivalent portion.

（３）効果
このように構成した車両用シートパッド及びその製造方法は、芯パッド２と表層パッド４とを備えて、芯パッド２が軟質ポリウレタン発泡成形体の見掛け密度よりも見掛け密度が小のビーズ発泡成形体で形成されるので、軽量化が進む。それでいて、軟質ポリウレタン発泡成形体で構成された表層パッド４の意匠面４ａ側に、着座乗員との当たり面部分４１が設けられているので、クッション性等の快適性は確保される。
また、表層パッド４の発泡成形で、発泡原料ｇが透孔２３に進出し、各透孔２３の下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａに発泡原料ｇが含浸一体化して、透孔２３内にポリウレタン発泡成形部４３を造る。芯パッド２に透孔２３を形成し、該透孔２３の下方側孔口２３ｂを含めて芯パッド下面２ｂを裏当て材５で覆い、さらに該透孔２３を埋めて裏当て材の部分５０ａに含浸一体化した表層パッド４の軟質ポリウレタン発泡成形部４３が形成されると、裏当て材の部分５０ａが表層パッド４に結合固定される。芯パッド２の下面２ｂに下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａを適宜設ければ、軽量化を推進して芯パッド２が大きくなっても、特許文献１のように裏当て材５が垂れ下がることがなくなる。芯パッド下面２ｂにおける裏当て材の部分５０ａによる表層パッド４との結合に加え、芯パッド下面２ｂよりも裏当て材５を大きくし、その周縁部５１での表層パッド４との結合を組み合わせれば、芯パッド下面２ｂに裏当て材５をより確実に沿わせたシートパッド１が得られる。芯パッド下面２ｂに裏当て材５を当てて、芯パッド下面２ｂの随所で裏当て材の部分５０ａが表層パッド４に結合固定するので、芯パッド下面２ｂに裏当て材５を密着させたシートパッド１になり、裏当て材５付きシートパッド１の形状を安定させ且つ組立てラインでの作業負担を軽減できる。 (3) Effect The vehicle seat pad and its manufacturing method configured in this manner include a core pad 2 and a surface layer pad 4, and the core pad 2 has a smaller apparent density than the apparent density of the flexible polyurethane foam molded product. Since it is formed of a bead foam molded product, the weight is reduced. Nevertheless, since the contact surface portion 41 with the seated occupant is provided on the design surface 4a side of the surface layer pad 4 made of the flexible polyurethane foam molded body, comfort such as cushioning is ensured.
Further, in the foam molding of the surface layer pad 4, the foamed raw material g advances into the through holes 23, and the foamed raw material g is impregnated and integrated into the backing material portion 50a that closes the lower side hole openings 23b of each through hole 23 to be transparent. A polyurethane foam molded portion 43 is formed in the hole 23. A through hole 23 is formed in the core pad 2, the lower surface 2b of the core pad including the lower hole opening 23b of the through hole 23 is covered with a backing material 5, and the through hole 23 is further filled to fill the backing material portion 50a. When the flexible polyurethane foam molded portion 43 of the surface layer pad 4 impregnated and integrated is formed, the backing material portion 50a is bonded and fixed to the surface layer pad 4. If the backing material portion 50a that closes the lower hole opening 23b is appropriately provided on the lower surface 2b of the core pad 2, even if the core pad 2 becomes large due to the promotion of weight reduction, the backing material is as in Patent Document 1. 5 will not hang down. In addition to the connection with the surface pad 4 by the backing material portion 50a on the lower surface 2b of the core pad, the backing material 5 is made larger than the lower surface 2b of the core pad, and the connection with the surface pad 4 on the peripheral edge 51 thereof can be combined. For example, a seat pad 1 can be obtained in which the backing material 5 is more reliably aligned with the lower surface 2b of the core pad. The backing material 5 is applied to the lower surface 2b of the core pad, and the backing material portion 50a is bonded and fixed to the surface pad 4 at various places on the lower surface 2b of the core pad. Therefore, the backing material 5 is brought into close contact with the lower surface 2b of the core pad. It becomes the pad 1, and the shape of the seat pad 1 with the backing material 5 can be stabilized and the work load on the assembly line can be reduced.

加えて、透孔２３の下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａが透孔２３周りの裏当て材５よりも芯パッド２の上面２ａ側に凹んで、図２のような凹部５０が形成されると、シートパッド１を車両に設置し使用された際の異音防止対策も整う。表層パッド４の発泡成形で、発泡原料ｇが透孔２３の下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａに含浸一体化して、該裏当て材５が軟質ポリウレタン発泡成形部４３と結合するが、含浸した裏当て材部分５０ａが時に異音源になる虞がある。発泡原料ｇが含浸一体化した該裏当て材の部分５０ａは硬化しており、場合によってはシートフレーム等の車体部材ＢＹと擦れ、異音を発生させる虞がある。下方側孔口２３ｂを塞ぐ裏当て材５の硬化部分を凹部５０に形成することによって、車体部材ＢＹと触れなくなり、異音発生を解消できる。
芯パッド下面２ｂよりも裏当て材５を大きくし、その周縁部５１で表層パッド４と結合させる場合も、周縁部５１が車体と触れないようにして異音発生を解消できる。芯パッド２の側面２５に表層パッド４の側壁部４５が積層し、該側壁部４５の下端面を、該側壁部４５に接する芯パッド２の側面の下端２５１から段差状に上面２ａ側へ後退する段差面４５１にする。且つ裏当て材５が芯パッド２を越えて該段差面４５１にまで覆い、表層パッド４の発泡成形で、側壁部４５が該段差面４５１上で裏当て材５の周縁部５１を含浸一体化させたシートパッド１とすることで、異音を防止できる。
芯パッド２に透孔２３を形成すると共に、下方側孔口２３ｂを塞ぐ裏当て材の部分５０ａを発泡原料ｇで含浸硬化させる構成を採用することで、大きな芯パッド２であっても、その下面２ｂに裏当て材５を確実に沿わせて保持できるシートパッド１になる。一方、異音発生の元になる裏当て材５の含浸硬化部分は、その裏当て材の部分５０ａを凹部５０に形成し、また裏当て材５の周縁部５１は段差面４５１に載せて表層パッド４(詳しくは側壁部４５)に一体化させているので、盤石な異音防止対策が図られたシートパッド１になっている。 In addition, the portion 50a of the backing material that closes the lower side hole opening 23b of the through hole 23 is recessed toward the upper surface 2a side of the core pad 2 with respect to the backing material 5 around the through hole 23, and the recess 50 as shown in FIG. When the seat pad 1 is installed in the vehicle and used, measures to prevent abnormal noise are also prepared. In the foam molding of the surface layer pad 4, the foaming raw material g is impregnated and integrated with the portion 50a of the backing material that closes the lower hole opening 23b of the through hole 23, and the backing material 5 is bonded to the flexible polyurethane foam molding portion 43. However, the impregnated backing material portion 50a may sometimes become a different sound source. The portion 50a of the backing material impregnated and integrated with the foaming raw material g is cured, and in some cases, it may rub against the vehicle body member BY such as a seat frame to generate an abnormal noise. By forming the cured portion of the backing material 5 that closes the lower hole opening 23b in the recess 50, it is possible to prevent the vehicle body member BY from coming into contact with the body member BY and to eliminate the generation of abnormal noise.
Even when the backing material 5 is made larger than the lower surface 2b of the core pad and the peripheral edge portion 51 is connected to the surface layer pad 4, it is possible to eliminate the generation of abnormal noise by preventing the peripheral edge portion 51 from touching the vehicle body. The side wall portion 45 of the surface layer pad 4 is laminated on the side surface 25 of the core pad 2, and the lower end surface of the side wall portion 45 recedes from the lower end 251 of the side surface of the core pad 2 in contact with the side wall portion 45 in a stepped manner toward the upper surface 2a side. The stepped surface 451 is set. Further, the backing material 5 covers the stepped surface 451 beyond the core pad 2, and the side wall portion 45 impregnates and integrates the peripheral edge portion 51 of the backing material 5 on the stepped surface 451 by foam molding of the surface layer pad 4. By using the seat pad 1 that has been moved, abnormal noise can be prevented.
By forming the through hole 23 in the core pad 2 and impregnating and curing the backing material portion 50a that closes the lower hole opening 23b with the foaming raw material g, even a large core pad 2 can be formed. The seat pad 1 is capable of securely holding the backing material 5 along the lower surface 2b. On the other hand, in the impregnated and cured portion of the backing material 5 that causes abnormal noise, the backing material portion 50a is formed in the recess 50, and the peripheral edge portion 51 of the backing material 5 is placed on the stepped surface 451 to form a surface layer. Since it is integrated with the pad 4 (specifically, the side wall portion 45), the seat pad 1 is provided with solid noise prevention measures.

さらに、裏当て材５を介在させて芯パッド２を上型９にセットし、芯パッド２,裏当て材５と一体の表層パッド４を発泡成形すると、発泡成形過程で発生する余剰ガスは、三次元網目構造の不織布製裏当て材５をつたって、パーティングラインへ円滑誘導できる。シートパッド１の成形不良が軽減する。 Further, when the core pad 2 is set on the upper mold 9 with the backing material 5 interposed therebetween and the surface pad 4 integrated with the core pad 2 and the backing material 5 is foam-molded, the excess gas generated in the foam molding process is generated. The non-woven fabric backing material 5 having a three-dimensional network structure can be smoothly guided to the parting line. Molding defects of the seat pad 1 are reduced.

さらにいえば、表層パッド４の発泡成形で、芯パッド２の透孔２３に充填される軟質ポリウレタン発泡成形部４３にアンカー効果を発揮させ、表層パッド４と芯パッド２とを一体化できる。意匠面４ａ側と反対の内面４ｂ側が芯パッド２の上面２ａに接合する表層パッド４を発泡成形するが、軟質ポリウレタン発泡体の表層パッド４とビーズ発泡成形体の芯パッド２との接着力は弱く、芯パッド２が表層パッド４から容易に剥がれる虞がある。そのため、特開2010-259525号公報,特開2012-171104号公報等の先行技術で両者の一体化を図る発明が提案されている。本発明は芯パッド２に貫通形成された透孔２３を埋める軟質ポリウレタン発泡成形部４３がアンカー効果を発揮し、表層パッド４に芯パッド２が接合一体化する優れた効果もある。上記先行技術の使用による作業負担増,コスト負担増もなしに、表層パッド４と芯パッド２との接合一体化を簡便且つ容易に実現でき、多大な効を奏する。透孔２３の下面２ｂ側で、孔径を大きくした拡径部２３１の一部を埋める軟質ポリウレタン発泡成形部４３１が設けられると、これがストッパになって、表層パッド４と芯パッド２との一体化を一層確実なものにできる。
かくのごとく、本車両用シートパッド及びその製造方法は、上述した種々の優れた効果を発揮し極めて有益である。 Further, in the foam molding of the surface layer pad 4, the flexible polyurethane foam molding portion 43 filled in the through hole 23 of the core pad 2 can exert an anchor effect, and the surface layer pad 4 and the core pad 2 can be integrated. The surface pad 4 whose inner surface 4b side opposite to the design surface 4a side is joined to the upper surface 2a of the core pad 2 is foam-molded, but the adhesive force between the surface pad 4 of the flexible polyurethane foam and the core pad 2 of the bead foam molding is It is weak and the core pad 2 may be easily peeled off from the surface pad 4. Therefore, inventions for integrating the two have been proposed by prior arts such as JP-A-2010-259525 and JP-A-2012-171104. In the present invention, the flexible polyurethane foam molded portion 43 that fills the through hole 23 that is formed through the core pad 2 exerts an anchor effect, and also has an excellent effect that the core pad 2 is joined and integrated with the surface layer pad 4. It is possible to easily and easily realize the joining and integration of the surface layer pad 4 and the core pad 2 without increasing the work load and the cost burden due to the use of the above-mentioned prior art, which is very effective. When a flexible polyurethane foam molded portion 431 that fills a part of the enlarged diameter portion 231 having a larger hole diameter is provided on the lower surface 2b side of the through hole 23, this serves as a stopper and integrates the surface layer pad 4 and the core pad 2. Can be made more reliable.
As described above, the seat pad for this vehicle and the method for manufacturing the same are extremely useful because they exhibit various excellent effects as described above.

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。芯パッド２,透孔２３,拡径部２３１,表層パッド４,軟質ポリウレタン発泡成形部４３,裏当て材５,発泡成形型７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。実施形態のシートパッド１は座部用クッションパッドにしたが、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 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. The shape, size, number, material, etc. of the core pad 2, the through hole 23, the enlarged diameter portion 231, the surface layer pad 4, the flexible polyurethane foam molded portion 43, the backing material 5, the foam molded mold 7, etc. are appropriate according to the application. You can choose. Although the seat pad 1 of the embodiment is a cushion pad for the seat, it can also be applied to a back pad for the backrest.

１シートパッド（クッションパッド）
２芯パッド
２ａ上面（芯パッド上面）
２ｂ下面（芯パッド下面）
２３透孔
２３１拡径部
２５側面
４表層パッド
４ａ意匠面
４１当たり面部分（着座乗員の当たり面部分）
４３透孔を埋める軟質ポリウレタン発泡成形部
４３１拡径部位の軟質ポリウレタン発泡成形部
４５側壁部
４５１段差面
５裏当て材
５０凹部
５０ａ裏当て材の部分（透孔の下方側孔口を塞ぐ裏当て材の部分）
５１周縁部
７発泡成形型
８１下型キャビティ面
９１上型キャビティ面
９１０側面下端セット部位
９１１段差部位
Ｃ１側壁部用キャビティ 1 Seat pad (cushion pad)
2 core pad 2a upper surface (core pad upper surface)
2b lower surface (underside of core pad)
23 through hole
231 Diameter expansion part 25 Side surface 4 Surface pad 4a Design surface 41 Contact surface part (contact surface part of seated occupant)
43 Flexible polyurethane foam molded part that fills the through holes
431 Flexible polyurethane foam molded part of diameter expansion part 45 Side wall part 451 Step surface 5 Backing material 50 Recession
50a Backing material part (the part of the backing material that closes the lower hole opening of the through hole)
51 Peripheral part 7 Foam molding type 81 Lower mold cavity surface 91 Upper mold cavity surface 910 Side lower end set part 911 Step part C1 Side wall cavity

Claims

少なくとも乗員が当接する側の当たり面部分を軟質ポリウレタン発泡体で形成した車両用シートパッドであって、
ブロック状に成形されたビーズ発泡成形体にして、その上面側から下面側へ貫通する透孔を設けた芯パッドと、
前記透孔の下方側孔口を含めて前記芯パッドの下面を覆う不織布からなる裏当て材と、
軟質ポリウレタン発泡体にして、その意匠面側に前記当たり面部分を形成すると共に、前記芯パッドの上面側から前記透孔の下方側孔口を塞ぐ前記裏当て材の部分までの該透孔を埋めて該裏当て材の部分に含浸一体化した軟質ポリウレタン発泡成形部を形成し、且つ前記意匠面側と反対の内面側が前記芯パッドの上面に接合する表層パッドと、を具備し、
且つ、前記透孔の下方側孔口を塞ぐ前記裏当て材の部分が前記透孔周りの裏当て材よりも前記芯パッドの上面側に凹んで、凹部が形成されたことを特徴とする車両用シートパッド。 A vehicle seat pad in which at least the contact surface portion on the side where the occupant comes into contact is made of soft polyurethane foam.
A bead foam molded body molded into a block shape, and a core pad provided with through holes penetrating from the upper surface side to the lower surface side.
A backing material made of a non-woven fabric that covers the lower surface of the core pad including the lower hole opening of the through hole, and
A flexible polyurethane foam is used to form the contact surface portion on the design surface side thereof, and the through hole from the upper surface side of the core pad to the portion of the backing material that closes the lower hole opening of the through hole is formed. It is provided with a surface layer pad that is embedded to form a flexible polyurethane foam molded portion that is impregnated and integrated in the backing material portion, and that the inner surface side opposite to the design surface side is joined to the upper surface of the core pad .
Further, the vehicle is characterized in that the portion of the backing material that closes the lower side hole opening of the through hole is recessed toward the upper surface side of the core pad with respect to the backing material around the through hole to form a recess. For seat pad.

前記透孔が芯パッド下面側の孔径を大きくした拡径部を有し、且つ該拡径部で径が大きくなった前記下方側孔口を塞ぐ前記裏当て材の前記凹部に、前記透孔を埋める前記軟質ポリウレタン発泡成形部に係る拡径部位の軟質ポリウレタン発泡成形部が含浸一体化した請求項１記載の車両用シートパッド。The through hole has an enlarged diameter portion on the lower surface side of the core pad, and the through hole is formed in the recess of the backing material that closes the lower hole opening whose diameter is increased by the enlarged diameter portion. The vehicle seat pad according to claim 1, wherein the flexible polyurethane foam molded portion of the diameter-expanded portion related to the flexible polyurethane foam molded portion is impregnated and integrated.

前記芯パッドの側面に前記表層パッドの側壁部が積層し、該側壁部の下端面を、該側壁部に接する前記芯パッドの側面の下端から段差状に上面側へ後退する段差面にし、且つ前記裏当て材が前記芯パッドを越えて該段差面にまで覆って、前記表層パッドが該段差面上の該裏当て材の周縁部にも含浸一体化した請求項１又は２に記載の車両用シートパッド。 The side wall portion of the surface layer pad is laminated on the side surface of the core pad, and the lower end surface of the side wall portion is made into a stepped surface that recedes from the lower end of the side surface of the core pad in contact with the side wall portion in a stepped manner toward the upper surface side. The vehicle according to claim 1 or 2, wherein the backing material extends over the core pad to the stepped surface, and the surface pad is impregnated and integrated with the peripheral edge of the backing material on the stepped surface. Seat pad for.

少なくとも乗員が当接する側の当たり面部分を軟質ポリウレタン発泡体で形成した車両用シートパッドの製造方法であって、
疣状凸部を形成した上型キャビティ面に不織布からなる裏当て材をセットすると共に、ブロック状に成形されたビーズ発泡成形体にして、その上面側から下面側へ貫通する透孔を設けた芯パッドを、前記凸部に該透孔を対向させ、下面側が前記裏当て材を介して上型キャビティ面に当接するようにして、該上型キャビティ面にセットし、該セットに伴い、前記凸部が前記透孔に嵌入し、該透孔を塞ぐ前記裏当て材の部分が該透孔周りの裏当て材よりも芯パッドの上面側に凹み、該裏当て材に凹部が形成された後、
次いで、下型キャビティ面上に軟質ポリウレタン発泡体用原料を注入すると共に型閉じし、
その後、意匠面側に前記当たり面部分を形成すると共に、前記芯パッドの上面側から前記透孔の下方側孔口を塞ぐ前記裏当て材の前記凹部までの前記透孔を埋めて該凹部に含浸一体化した軟質ポリウレタン発泡成形部を形成し、且つ前記意匠面側と反対の内面側が前記芯パッドの上面に接合する軟質ポリウレタン発泡体の表層パッドを発泡成形したことを特徴とする車両用シートパッドの製造方法。 It is a method for manufacturing a vehicle seat pad in which at least the contact surface portion on the side where the occupant comes into contact is made of a flexible polyurethane foam.
A backing material made of non-woven fabric was set on the upper cavity surface on which the wart-shaped convex portion was formed, and a bead foam molded body formed into a block shape was provided with through holes penetrating from the upper surface side to the lower surface side. core pads, are opposed to the transparent hole in the convex portion, so as to lower surface side comes into contact with the upper die cavity surface through the backing material, set on the upper mold cavity surface, with the said set, wherein The convex portion fits into the through hole, and the portion of the backing material that closes the through hole is recessed toward the upper surface side of the core pad with respect to the backing material around the through hole, and a recess is formed in the backing material. rear,
Next, the raw material for the flexible polyurethane foam is injected onto the lower mold cavity surface and the mold is closed.
After that, the contact surface portion is formed on the design surface side, and the through hole from the upper surface side of the core pad to the recess of the backing material that closes the lower hole opening of the through hole is filled in the recess . A vehicle seat characterized in that a flexible polyurethane foam molded portion integrated with impregnation is formed, and a surface pad of a flexible polyurethane foam whose inner surface side opposite to the design surface side is joined to the upper surface of the core pad is foam molded. How to make the pad.

前記透孔に芯パッド下面側の孔径を大きくした拡径部を形成して、
該拡径部で径が大きくなった前記下方側孔口を塞ぐ前記裏当て材の前記凹部に含浸一体化する前記軟質ポリウレタン発泡成形部に係る拡径部位の軟質ポリウレタン発泡成形部を形成した請求項４記載の車両用シートパッドの製造方法。 An enlarged diameter portion having a larger hole diameter on the lower surface side of the core pad is formed in the through hole.
A claim for forming a soft polyurethane foam molded portion of a diameter-expanded portion related to the flexible polyurethane foam molded portion that is impregnated and integrated into the recess of the backing material that closes the lower hole opening whose diameter is increased by the enlarged diameter portion. Item 4. The method for manufacturing a vehicle seat pad according to item 4.

前記型閉じに伴い、インサートされた芯パッドの側面の外側に前記表層パッドの側壁部用キャビティが形成されるようにして、その上型キャビティ面に、前記芯パッドの側面下端セット部位よりも段差状に芯パッド上面側に後退する段差部位を設けて、該段差部位を含めた上型キャビティ面に前記裏当て材をセットする請求項４又は５に記載の車両用シートパッドの製造方法。 Along with the closing of the mold, a cavity for the side wall portion of the surface layer pad is formed on the outside of the side surface of the inserted core pad, and a step is formed on the upper mold cavity surface with respect to the side lower end setting portion of the core pad. The method for manufacturing a vehicle seat pad according to claim 4 or 5, wherein a step portion retreating to the upper surface side of the core pad is provided in a shape, and the backing material is set on the upper die cavity surface including the step portion.