JP6854640B2 - Seat pad and its manufacturing method - Google Patents

Description

The present invention relates to a seat pad used for a seat of a vehicle such as an automobile and a method for manufacturing the same.

As a method for manufacturing a cushion in which foams having different hardness are laminated, for example, there is one disclosed in Patent Document 1. In the method disclosed in Patent Document 1, first, a flat molded body having holes is laid in the cavity, and the first reaction mixture still in a fluid state is injected onto the flat molded body to prepare the first reaction mixture. A first foam layer is obtained by flowing through a hole into a space located below it and foaming there. Next, the first foam layer is filled with the second reaction mixture in a state of being creamed to the extent that it cannot pass through the holes of the planar molded product into the cavities remaining in the upper and side portions of the planar molded product. A second foam layer is obtained by superimposing on the above.

Japanese Unexamined Patent Publication No. 2-14113

However, as in Patent Document 1, in the method of attaching the flat molded body to the mold with an adhesive tape or pressing and fixing the flat molded body with a needle, the flat molded body is not held between the adhesive tape or the needle. , The foaming pressure associated with the foaming of the reaction mixture causes the planar compact to undulate. In this way, when the flat molded body is point-fixed to the mold, the thicknesses of the first foam layer and the second foam layer do not meet the design, and the thickness varies depending on the part, so that the ride is comfortable. Cushion performance cannot be obtained.

That is, the present invention has been proposed in view of the above-mentioned problems related to the prior art, and provides a seat pad having a comfortable ride and good cushioning performance, and a method for manufacturing the same. The purpose is.

In order to overcome the above-mentioned problems and achieve the intended purpose, the seat pad of the invention according to claim 1 of the present application can be used.
A plurality of grooves extending along the support surface as well as opening to the support surface on the occupant side of the pad body, and
A frame portion arranged on the pad body corresponding to the groove portion and
A section connected to the frame portion and erected between the frame portions arranged in parallel or arranged at different angles and arranged on the pad body, and extending between two foam layers having different physical characteristics in the pad body. The gist is that it is equipped with members.
According to the invention of claim 1, since the partition members are connected to the frame portion and erected between the frame portions arranged in parallel or arranged at different angles, the partition members are hard to shift and the two foam layers are formed. The thickness can be as designed or closer to the design. As a result, a comfortable cushioning performance can be obtained.

In the invention according to claim 2, the two foam layers are arranged on the side distant from the occupant with the partition member in between, as compared with the first foam layer arranged on the occupant side with the partition member in between. The second foam layer was set hard,
In the second foam layer, a spacer separate from the second foam layer is provided between the protective member arranged so as to cover the side opposite to the support surface of the pad body and the partition member. The gist is that it is embedded.
According to the invention of claim 2, since the spacer can more appropriately prevent the displacement of the partition member, the thickness of the two foam layers becomes as designed or close to the design, and the cushioning performance is more excellent in riding comfort. Is obtained.

In order to overcome the above-mentioned problems and achieve the desired object, the method for manufacturing a seat pad according to claim 3 of the present application is:
Attached to the top of a ridge that opens into a support surface on the occupant side and defines a groove extending along the support surface so as to hold the partition member linearly along the extending direction of the ridge. The partition member is placed in the cavity of the molding die by passing it between ridges arranged in parallel or at different angles.
The first foam raw material injected through the partition member is foamed in the first region surrounded by the ridge and the partition member in the cavity, and the first foam layer made of the first foam raw material is formed. Molded in the first region,
When the second foam raw material injected into the second region other than the first region in the cavity is foamed and the second foam layer made of the second foam raw material is formed in the second region, the said The gist is that it is formed so as to be overlapped with the first foam layer.
According to the invention of claim 3, since the partition member is held linearly with respect to the molding die along the extending direction of the ridge, the partition member is positioned in a wavy manner due to the foaming pressure of the foam raw material. It can be prevented from shifting. Therefore, in the obtained pad body, the thickness of the two overlapping foam layers is as designed or close to the design, so that a comfortable cushioning performance can be obtained.

In the invention according to claim 4, a frame portion is attached to the partition member so as to extend corresponding to the ridge.
The frame portion is attached along the top of the ridge to hold the compartment member continuously with respect to the ridge in the extending direction of the ridge, and of the ridges arranged in parallel or at different angles. The gist is to erection in a stretched state.
According to the invention of claim 4, by holding the frame portion attached to the partition member on the top of the ridge, the partition member can be easily set in the molding die. Further, by continuously holding the partition member along the ridge by the frame portion, the displacement of the partition member can be more preferably prevented.

The gist of the invention according to claim 5 is that the frame portion made of a ferromagnetic material is held by a holding means made of a magnet provided on the ridge, and the partition member is arranged in the cavity.
According to the invention of claim 5, by holding the frame portion by the holding means made of a magnet, it is possible to more easily set the partition member in the molding die. Further, since the partition member can be held so as not to be separated from the ridge, the displacement of the partition member can be more preferably prevented.

In the invention according to claim 6, the second foam layer is molded in a state where a spacer is arranged between the partition member in the second region and the mold surface of the molding mold facing the partition member. Is the gist.
According to the invention of claim 6, the spacer arranged between the partition member and the mold surface facing the partition member can prevent the partition member from being displaced due to the foaming pressure of the first foam raw material.

According to the seat pad according to the present invention, it has a good cushioning performance that is comfortable to ride. According to the method for manufacturing a seat pad according to the present invention, it is possible to easily manufacture a seat pad that is comfortable to ride and has good cushioning performance.

It is a schematic perspective view which shows the sheet provided with the pad for a sheet which concerns on a preferred embodiment of this invention. It is the schematic perspective view which shows the pad for the sheet of an Example by cutting out a part. FIG. 2 is a cross-sectional view taken along the line AA of FIG. FIG. 2 is a cross-sectional view taken along the line BB of FIG. It is a schematic perspective view which shows the molding mold which manufactures the pad for a sheet of an Example. It is a top view which shows the 1st mold of the molding mold of an Example. It is explanatory drawing which shows the manufacturing process by the manufacturing method of an Example. It is explanatory drawing which shows the manufacturing process by the manufacturing method of an Example. It is explanatory drawing which shows the measurement point of a test.

Next, the seat pad and the method for manufacturing the seat pad according to the present invention will be described below with reference to the accompanying drawings with reference to suitable examples. In the embodiment, the seat pad 20 used for the seat 10 installed in the passenger room of the passenger car will be described.

As shown in FIG. 1, the seat 10 according to the embodiment includes a seat portion 12 that supports the lower body of the occupant, and a backrest portion 14 that is tiltably installed at the rear portion of the seat portion 12 to support the upper body of the occupant. It is basically composed of a headrest 16 which is installed on the upper part of the backrest portion 14 and supports the head of the occupant. Each part 12, 14, 16 of the sheet 10 is attached or covered on the front side of the sheet pad 20 whose main body is a foam such as polyurethane so as to cover the skin material 18 such as cloth, synthetic leather or genuine leather. It is composed of. Since the seat portion 12 and the backrest portion 14 have similar basic structures and the same manufacturing method, the seat pad 20 forming the seat portion 12 will be described below. Further, in the description of the seat pad 20 forming the seat portion 12, the up / down / front / rear / left / right are referred to with reference to the installation state in the vehicle.

As shown in FIG. 2, the seat pad 20 includes a front support portion 22 that mainly supports the thighs of the occupant sitting on the seat, a rear support portion 24 that mainly supports the buttocks of the occupant, and an occupant. It is provided with a pad body 21 which is roughly divided into left and right side support portions 26 and 26 which are supported from the left and right. The pad body 21 is basically made of a foam material such as polyurethane having a cushioning property. Further, the seat pad 20 includes a protective member 28 provided so as to cover the lower surface of the pad body 21 on the vehicle body side, and when the seat pad 20 is installed on a metal frame constituting the skeleton of the seat, the protective member 28 is a metal frame. It comes in contact with. A flexible material such as a non-woven fabric or a cloth is used for the protective member 28 to prevent abnormal noise from being generated between the protective member 28 and the metal frame due to vibration or the like.

As shown in FIG. 2, the pad body 21 is formed with a plurality of groove portions 30 that are open to the support surface on the occupant side of the pad body 21 and extend along the support surface. The groove portion 30 is basically arranged so as to extend to the boundary of each of the support portions 22, 24, 26. In the pad body 21 of the embodiment, two vertical groove portions 30, 30 that separate the front support portion 22, the rear support portion 24, and the side support portion 26 are arranged so as to extend in the front-rear direction and to be separated from each other in the left-right direction. .. Further, the pad main body 21 is provided with a horizontal groove portion 30 which is located between the two vertical groove portions 30 and 30 and which extends to the left and right in connection with each vertical groove portion 30, and the front support portion is provided by the horizontal groove portion 30. 22 and the rear support unit 24 are separated. The groove 30 is used to pull the skin 18 into the groove 30 (inside the pad body 21) to apply tension to the seat 18 when the skin 18 is attached to the seat pad 20.

The pad body 21 is designed with the composition of the foam raw materials 64,68 and the like so as to have the desired mechanical properties (for example, hardness, elastic modulus, etc.) according to the use of the sheet pad 20. As shown in FIGS. 2 to 4, in the pad body 21, the front support portion 22 and the rear support portion 24 are composed of two foam layers 32 and 34 having different physical characteristics, and the side support portion 26 is a single foam. It is composed of a body layer 34. Specifically, the front support portion 22 and the rear support portion 24 are composed of a first foam layer 32 and a second foam layer 34 set to be harder than the first foam layer 32, and the first one. The foam layer 32 and the second foam layer 34 are laminated one above the other in the direction in which the load from the occupant is applied (thickness direction). Further, in the front support portion 22 and the rear support portion 24, the support surface side of the pad body 21 is composed of a relatively flexible first foam layer 32, and the side opposite to the support surface of the pad body 21 is relatively hard. 2 It is composed of a foam layer 34. The side support portion 26 is composed of a second foam layer 34. The pad body 21 does not have the foam layers 32, 34 bonded to each other with an adhesive or the like, but both foam layers 32, 34 are integrated by molding the foam layers 32, 34 in the same mold. It has become.

As shown in FIGS. 2 to 4, the seat pad 20 is erected between the frame portion 36 arranged corresponding to the groove portion 30 in the pad main body 21 and the frame portions 36 connected to the frame portion 36 and arranged side by side. It is provided with a partition member 38 arranged on the pad body 21. The frame portion 36 is an elongated rod-shaped or plate-shaped member, is arranged along the length along the groove portion 30 extending in the front-rear or left-right direction with a required length, and extends over a dimension equal to or close to the total length of the groove portion 30. It is extended or arranged so as to extend. As the frame portion 36, a long object such as a wire, a bar or a plate can be used, and since it is easy to handle at the time of manufacturing, a wire is used in the examples. The frame portion 36 corresponds to a plurality of groove portions 30, whether it is configured by one corresponding to one groove portion 30, a plurality of frames corresponding to one groove portion 30 are arranged side by side, or a plurality of frames are connected to each other. It may be integrally formed in the formed shape, or may be connected in plurality corresponding to the plurality of groove portions 30. In the embodiment, the frame portion 36 is also arranged in the shape of a “day” corresponding to the groove portion 30 arranged in the shape of a “day” on the support surface of the pad body 21. A metal material, a synthetic resin material, or the like can be used for the frame portion 36, and in the embodiment, the frame portion 36 is fixed to the molding die 50 by using the holding means 52 made of a magnet (see FIGS. 5 and 6). Iron, which is a ferromagnet that sticks to magnets, is used.

As shown in FIGS. 3 and 4, the partition member 38 is a sheet-like member extending between the two foam layers 32 and 34 having different physical properties in the pad body 21, and is the first foam layer 32. It has an opening through which the first foam raw material 64 forming the above can pass. Specifically, the partition member 38 is located inside the pad main body 21 between the left and right side support portions 26, 26, and is arranged corresponding to the front support portion 22 and the rear support portion 24. The first foam layer 32 and the second foam layer 34 are integrated through the partition member 38 and the openings provided in the partition member 38. Further, the upper and lower two foam layers 32 and 34 are arranged on the side farther from the occupant with the partition member 38 sandwiched from the first foam layer 32 arranged on the occupant side with the partition member 38 interposed therebetween. The second foam layer 34 is set to be hard.

As the partition member 38, a mesh-like material or a material having a large number of holes formed through the partition member 38 can be used. For example, a mesh sheet in which threads made of natural fibers or synthetic fibers are arranged in a mesh-like shape, a mesh such as cheesecloth, or the like. Coarse fabrics and non-woven fabrics can be used. Further, the partition member 38 is preferably flexible from the viewpoint of improving handleability when set in the molding die 50. The partition member 38 has an edge portion attached to the frame portion 36 and is connected to the frame portion 36, and is hung between the frame portions 36, 36 arranged in the front-rear or left-right direction. The partition member 38 is formed in a quadrangle shape in accordance with the quadrangular region (arrangement shape of the groove portion 30) of the front support portion 22 and the rear support portion 24. The partition member 38 is connected to a frame portion 36 whose front-rear and left-right edges are arranged along the edge, and is connected to a frame portion 36 whose central portion in the front-rear direction extends to the left and right. In the partition member 38, the four edges are held by the frame 36 over the entire edge, and the longitudinal central portion in the front-rear direction is also held by the frame 36.

As shown in FIGS. 3 and 4, in the second foam layer 34, the second foam is formed between the protective member 28 and the partition member 38 arranged so as to cover the side opposite to the support surface of the pad body 21. A spacer 40 separate from the body layer 34 is embedded. The spacer 40 is arranged so as to be in contact with both or one of the protective member 28 and the partition member 38, and is formed in a polygonal columnar shape such as a square or a columnar shape. The spacer 40 may have different physical characteristics from the second foam layer 34, but has the same physical characteristics as the second foam layer 34 so as not to impair the performance such as cushioning property developed by the second foam layer 34. Is preferable. As the spacer 40, for example, a urethane block obtained by molding crushed polyurethane into a block shape, slab urethane, or the like can be used.

Next, a method of manufacturing the seat pad 20 according to the embodiment will be described. As shown in FIGS. 7 and 8, the seat pad 20 can be manufactured by foaming and molding the pad body 21 with a molding die 50 in which the partition member 38 and the protective member 28 are set. As shown in FIGS. 5 and 7B, the molding mold 50 includes a first mold 54 that defines the support surface side of the pad body 21, and a second mold 56 that defines the side opposite to the support surface of the pad body 21. The first type 54 is arranged on the lower side. That is, the pad body 21 is molded in the molding die 50 in an upside-down orientation with the installation posture on the vehicle.

As shown in FIGS. 5 and 6, the first mold 54 includes a ridge 58 that defines a groove 30 provided on the support surface of the pad body 21, and the ridge 58 that protrudes from the mold surface that defines the support surface is provided. It extends in the shape of a "day" in accordance with the vertical groove portion 30 and the horizontal groove portion 30 to be obtained. The first type 54 includes a holding means 52 capable of holding the partition member 38 linearly along the extending direction of the ridge 58 with respect to the top of the ridge 58. In the first type 54, the partition member 38 is attached to the top of the ridge 58 in a linear shape along the extending direction of the ridge 58 by the holding means 52, and the ridges arranged in front, back, left and right are arranged. The partition member 38 can be set while being passed between 58 and 58.

Specifically, the holding means 52 is configured to be able to hold the frame portion 36 attached to the partition member 38, and by holding the frame portion 36 at the top of the ridge 58, the partition member 38 is held by the frame portion 36. The ridge 58 is continuously held along the extending direction. Further, the holding means 52 is configured so that the holding of the frame portion 36 can be released when the pad main body 21 is molded with the molding die 50 and then the pad main body 21 is removed from the mold. Here, the holding means 52 not only holds the frame portion 36 so as to regulate the movement of the frame portion 36 in the front-rear and left-right directions, but also holds the frame portion 36 so as to regulate the movement in the vertical direction to some extent. The holding means 52 can hold the partition member 38 hung between the ridges 58, 58 arranged side by side or front and back in a state where tension is applied to the front and back or left and right, and the partition member 38 can hold the ridge 58. It can be held so that it does not move upward from. As the holding means 52, a magnet that attracts the frame portion 36 made of a ferromagnetic material such as iron, a clip that holds the frame portion 36 by sandwiching the frame portion 36, or the like can be used, and the frame portion 36 can be easily attached and detached. It is preferable to use a magnet as in.

The manufacturing method using the above-mentioned molding die 50 will be described. The frame portion 36 is attached to the edge of the partition member 38 and the central portion in the front-rear direction in accordance with the arrangement of the ridges 58 in the first type 54. As shown in FIG. 5, in the partition member 38, for example, two frame portions 36, 36 are arranged in series on the longitudinal edge extending in the front-rear direction, and 1 on the short edge extending in the left-right direction. The frame portion 36 of the book is arranged, and the frame portion 36 is arranged so as to extend to the left and right between the two frame portions 36, 36 arranged along the longitudinal edge. Further, in the partition member 38, the adjacent frame portions 36, 36 are not directly connected to each other, and the partition members 38 can be bent between the adjacent frame portions 36, 36. The frame portion 36 is fixed to the partition member 38 so as not to move in the front-rear / left-right direction and the up-down direction. As a method of fixing the frame portion 36, for example, the frame portion 36 may be attached or adhered with an adhesive tape or the like, the frame portion 36 may be passed through a hole formed in a linear arrangement in the partition member 38 like a sewing thread, or the partition member 38 may be fixed in advance. Various methods can be adopted, such as folding back the end portion and sewing to form an annular portion, and passing the frame portion 36 through the annular portion. Since it is easy to attach, an adhesive tape is used in the examples. There is. The frame portion 36 is attached to the partition member 38 so as to hold the partition member 38 over the entire frame portion 36. Then, in the partition member 38, the entire circumference of the edge and the central portion inside are held in a frame shape by the frame portion 36 having a plurality of strips.

Next, the partition member 38 to which the frame portion 36 is attached is set in the first mold 54 (see FIGS. 5 and 7 (a)). The partition member 38 is attached to the top of the ridges 58 and is placed in the cavity 60 by passing it between the ridges 58, 58 arranged in the front-rear or left-right direction. More specifically, the partition member 38 extends back and forth to the ridge 58 that defines the vertical groove portion 30 by holding the frame portion 36 by the holding means 52 made of a magnet provided in the ridge 58. The frame portion 36 is held, and the longitudinal edge is continuously held with respect to the ridge 58 along the extending direction of the ridge 58. Similarly, in the partition member 38, the frame portion 36 extending to the left and right is held by the ridge 58 defining the lateral groove portion 30, and the short edge and the front and rear central portions are held against the ridge 58. It is held continuously along the extending direction of 58. The partition member 38 attaches a frame portion 36 extending back and forth to a ridge 58 defining a vertical groove portion 30 so that tensions are applied to both longitudinal edges in opposite directions. Similarly, the partition member 38 attaches a frame portion 36 extending to the left and right to the ridge 58 defining the lateral groove portion 30 so that tension is applied to both edges of the short side in opposite directions. .. A force is always applied to the frame portion 36 toward the top of the ridge 58 by the holding means 52 made of a magnet so that the attachment portion of the partition member 38 to the ridge 58 does not separate from the top of the ridge 58. Be retained.

Next, the liquid first foam raw material 64 to be the first foam layer 32 is injected through the partition member 38 into the first region 62 surrounded by the ridge 58 and the partition member 38 in the first mold 54 (FIG. 7 (a)). Further, the liquid second foam raw material 68 to be the second foam layer 34 is injected into the second region 66 other than the first region 62 in the first type 54. The second foam raw material 68 is injected into, for example, a portion of the second region 66 that serves as a side support portion 26. Further, the second foam raw material 68 is set at the same time as the injection timing of the first foam raw material 64, at a timing that coincides with the injection timing of the first foam raw material 64, at a timing that deviates from the injection timing of the first foam raw material 64, and the like. Just inject.

As shown in FIG. 7B, a protective member 28 is attached to the second mold 56, and the protective member 28 is set by closing the molding die 50. Further, a spacer 40 is attached to at least one of the surface of the protective member 28 facing the cavity 60 and the surface of the partition member 38 facing the second region 66 (protective member 28 in the embodiment) with adhesive tape or the like, and molding is performed. When the mold 50 is closed, the spacer 40 is arranged between the partition member 38 in the second region 66 and the mold surface facing the partition member 38 (see FIG. 8A). The spacer 40 may be fixed to at least one of the protective member 28 and the partition member 38 with an adhesive tape or the like, or the spacer 40 may be fixed by the shape of the molding die 50 (convex shape, concave shape, etc.). Good. By promoting the foaming and solidification of the foam raw materials 64 and 68 by heating the molding die 50 under predetermined conditions or the like, the first foam raw material 64 gradually foams and rises (FIG. 8 (a)). The first foam raw material 64, which has a higher viscosity than that at the time of injection, can hardly pass through the partition member 38, and the first foam layer 32 is formed in the first region 62. Further, although the second foam raw material 68 gradually foams and rises, wraps around from the side and overlaps the upper part of the first region 62, the second foam raw material 68 having a higher viscosity than that at the time of injection is a partition member. The second foam layer 34 is formed in the second region 66 with almost no passage through 38.

In this way, a pad body 21 in which two foam layers 32 and 34 having different physical properties are laminated and integrated in the thickness direction, and a sheet pad 20 in which a protective member 28 is integrated with the pad body 21 can be obtained. (Fig. 8 (b)). Then, by opening the molding die 50 and lifting the seat pad 20 from the first mold 54, the frame portion 36 is removed from the holding means 52 made of a magnet, and the seat pad 20 can be removed from the mold.

In the above-mentioned seat pad 20, a partition member 38 extending between the vertically overlapping foam layers 32 and 34 is connected to the frame portion 36 and held by the frame portion 36, and is arranged in the front-rear and left-right directions. It is erected and stretched between the frames 36 and 36. Therefore, the partition member 38 does not easily shift, and the thicknesses of the two foam layers 32 and 34 can be made as designed or closer to the design. As a result, the seat pad 20 can obtain a comfortable and good cushioning performance in which the physical properties of the two foam layers 32 and 34 are combined. The front support portion 22 and the rear support portion 24 composed of the first foam layer 32 are softer than the side support portion 26 composed of the second foam layer 34, so that when the occupant sits on the seat pad 20. In addition, it sinks greatly and can firmly hold the thighs and buttocks of the occupant. On the other hand, since the side support portion 26 is harder than the front support portion 22 and the rear support portion 24, even if the occupant sits on the seat pad 20, the side support portion 26 is less likely to sink and does not bottom out. It will be possible to support it firmly. In particular, the seat pad 20 supports the load input from the support surface by making the partition member 38 erected and stretched between the frame portions 36, 36 arranged in the front-rear and left-right directions function like a hammock. You can also let it. Further, since the frame portion 36 of the seat pad 20 is arranged along the groove portion 30, it can be used as a fixing target (fixing member) when the skin material 18 is inserted into the groove portion 30 and fixed by a fixing tool such as a hog ring. Can also work. Then, by sharing the frame portion 36 as the fixing target of the skin material 18, it is possible to reduce the number of fixing members for fixing the skin material 18.

In the sheet pad 20, a spacer 40 that is separate from the second foam layer 34 is arranged between the partition member 38 and the protective member 28, so that the spacer 40 makes the displacement of the partition member 38 more appropriate. Can be prevented. As a result, the thicknesses of the two laminated foam layers 32 and 34 can be made as designed or closer to the design, and the pad body 21 can have a comfortable and good cushioning performance. Further, it is also possible to adjust the cushioning property of the entire second foam layer 34 by changing the spacer 40 to be arranged.

In the case of point fixing in which the partition member 38 is inserted into the pin provided on the ridge 58 as in the conventional case, the partition member 38 undulates between the point-fixed portions due to the foaming pressure, and the foam layers 32, 34. The thickness of is not as designed. On the other hand, according to the manufacturing method of the embodiment, since the partition member 38 is linearly held with respect to the first type 54 along the extending direction of the ridge 58, the foam raw materials 64,68 It is possible to prevent the partition member 38 from being displaced due to waviness or the like due to the foaming pressure of the above. Therefore, the obtained pad body 21 can adjust the thickness of the two laminated foam layers 32, 34 as designed or designed by a simple method of holding the partition member 38 linearly with respect to the first mold 54. Can be closer, and therefore good cushioning performance with a comfortable ride is obtained.

In the manufacturing method, the frame portion 36 is attached to the partition member 38 so as to extend corresponding to the ridge 58, and the frame portion 36 is attached along the top of the ridge 58, whereby the partition member 38 is attached. The ridges 58 are continuously held in the extending direction of the ridges 58. By attaching the long frame portion 36 to the partition member 38 in this way, only by aligning the frame portion 36 with the ridge 58, the portion of the partition member 38 corresponding to the length of the frame portion 36 is the first type. It can be aligned to 54 all at once. In this way, it is possible to facilitate the setting of the partition member 38 on the first type 54. Further, the partition member 38 is continuously held along the ridges 58 by the frame portion 36, and the section member 38 is extended in a state where tension is applied between the ridges 58 and 58 arranged in the front-rear and left-right directions. Therefore, the misalignment of the partition member 38 can be more preferably prevented.

In the manufacturing method, since the frame portion 36 made of a ferromagnetic material is held by the holding means 52 made of a magnet provided in the ridge 58, it is easier to set the partition member 38 to the first type 54. Can be done. Further, in the case of point fixing in which the partition member 38 is inserted into the pin provided on the ridge 58, it is not possible to prevent the partition member 38 from coming off from the pin. On the other hand, according to the manufacturing method of the embodiment, the frame portion 36 can be held so as not to be separated from the ridge 58 by the magnetic force of the holding means 52, so that the partition member 38 is displaced in the height direction. Can be more preferably prevented.

In the manufacturing method, the second foam layer 34 is foamed and molded with the spacer 40 arranged between the partition member 38 in the second region 66 and the mold surface of the first mold 54 facing the partition member 38. Therefore, it is possible to restrict the partition member 38 from being displaced upward by the spacer 40. Therefore, since it is possible to prevent the partition member 38 from being displaced due to the foaming pressure of the first foam raw material 64, the thicknesses of the two laminated foam layers 32 and 34 can be made as designed or closer to the design. , Good cushioning performance that is comfortable to ride can be obtained.

(Test example)
Sheet pads of Test Example 1, Test Example 2 and Comparative Example were produced, and the variation in the thickness of the foam layer and the degree of waviness were measured. Both the test example and the comparative example have the same shape, and the first foam layer is made of polyurethane which is softer than the second foam layer. In Test Example 1, a partition member to which a frame portion made of a wire (wire) is attached is formed by foaming and molding two foam layers in a state where the frame portion is held by a ridge by a holding means made of a magnet. Is. In Test Example 2, in addition to the conditions of Test Example 1, two foam layers are foamed and molded with a spacer arranged between the partition member and the protective member. In the comparative example, two foam layers are foamed and molded in a state where the partition member is hooked on a pin protruding from the top of the ridge. The test example and the comparative example were molded under the same conditions in the same foam molding step as the manufacturing method described in the examples.

As shown in FIG. 9, test examples and comparative examples are supported from the pad body at locations corresponding to each series (IV) in the left-right direction for each cross section (circles 1 to 5) broken in the front-rear direction. The thickness of the first foam layer from the surface to the partition member was measured. The results are shown in Table 1. In FIG. 9, each part is designated by the same reference numerals as those in the embodiment.

As shown in Table 1, it is clear that the variation in the thickness and the waviness of the foam layer can be prevented by setting the partition member in the molding die while holding the partition member linearly in the frame portion. Further, it can be seen that by inserting a spacer between the partition member and the protective member, variation in thickness and waviness of the foam layer can be more preferably prevented.

(Change example)
The configuration is not limited to the above-mentioned configuration, and can be changed as follows, for example.
(1) In the embodiment, the frame portion is arranged in the shape of "day" corresponding to the ridges (grooves) arranged in the shape of "day", but the frame portion is not limited to this, and the "b" The frame portion may be arranged in an appropriate shape such as a character shape, a "U" shape, a "D" shape, or a "U" shape.
(2) The partition member is not limited to a configuration in which the partition members are hung between the frame portions (protrusions) parallel to each other in the front-rear direction or the left-right direction. It may be a structure to be passed over.
(3) In the pad body, apart from the frame part corresponding to the groove part (referred to as the corresponding frame part when particularly distinguished), the frame part which is arranged between the corresponding frame parts and deviates from the position of the groove part (particularly distinguishes). In that case, a non-corresponding frame portion) may be provided. In this case, the non-corresponding frame portion may be provided by connecting to the corresponding frame portion.
(4) The present invention can be used not only for the seat pad used for the seat portion of the seat, but also for the seat pad used for other portions such as the backrest portion. It can also be applied not only to the front seats of a vehicle but also to the rear seats.
(5) The present invention can be applied not only to seat pads used for seats of vehicles such as automobiles, but also to seat pads used for seats of railway vehicles and seats of aircraft.
(6) The present invention can be applied not only to seat pads used for seats of vehicles such as automobiles, but also to seat pads used for furniture and the like.

21 pad body, 28 protective member, 30 groove, 32 first foam layer (foam layer),
34 Second foam layer (foam layer), 36 frame part, 38 compartment member, 40 spacer,
50 Mold, 52 Holding Means, 58 Protrusions, 60 Cavities, 62 First Region,
64 1st foam raw material, 66 2nd region, 68 2nd foam raw material

Claims (5)

A sheet pad that is a molded product
In the seat pad, the first foam layer arranged on the occupant side and the second foam layer which has different physical characteristics from the first foam layer and is arranged so as to be overlapped on the side farther from the occupant with respect to the first foam layer. The pad body with the body layer and
A plurality of grooves extending along the support surface as well as opening to the support surface on the occupant side of the pad body,
To the bottom of the groove definitive in the pad body, it arranged to extend along the groove portion, a frame portion detachable from ridge to form the groove portion in the mold for molding the pad body,
And a partition member disposed between the first foam layer and said second foam layer before Symbol pad body,
The partition member is a mesh-like material or a sheet-like material having a plurality of holes through which a liquid foam material to be the first foam layer can pass.
The partition member is connected to the frame portion and is erected between the frame portions in parallel and / or between the frame portions arranged at different angles.
A seat pad characterized in that an edge portion of the partition member connected to the frame portion is linearly supported along the frame portion. The second foam layer is set to be harder than the first foam layer.
In the second foam layer, a spacer separate from the second foam layer is provided between the protective member arranged so as to cover the side opposite to the support surface of the pad body and the partition member. The seat pad according to claim 1, which is embedded. By attaching the frame portion along the ridge to the top of the ridge that opens to the support surface on the occupant side and defines the groove extending along the support surface , the edge portion is along the frame portion. A linearly supported partition member is passed between parallel ridges and / or ridges arranged at different angles, and the partition member is placed in a molding cavity in a stretched state between the ridges. And
The first foam raw material injected through the partition member is foamed in the first region surrounded by the ridge and the partition member in the cavity, and the first foam layer made of the first foam raw material is formed. Molded in the first region,
When the second foam raw material injected into the second region other than the first region in the cavity is foamed and the second foam layer made of the second foam raw material is formed in the second region, the said A method for manufacturing a sheet pad, which is characterized by being formed so as to be overlapped with a first foam layer. The method for manufacturing a seat pad according to claim 3, wherein the frame portion made of a ferromagnetic material is held by a holding means made of a magnet provided in the ridge, and the partition member is arranged in the cavity. The sheet according to claim 3 or 4, wherein the second foam layer is molded in a state where a spacer is arranged between the partition member in the second region and the mold surface of the molding mold facing the partition member. How to manufacture the pad.

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