JP7656563B2 - Manufacturing method of reinforcing member and manufacturing method of cushion body using reinforcing member - Google Patents

Description

The present invention relates to a method for manufacturing a reinforcing member and a method for manufacturing a cushion body using a reinforcing member.

For example, cushion bodies used in vehicles and the like are sometimes used with a reinforcing member placed on the back side of a cushion pad made of a foam molded body. The reinforcing member is made of a nonwoven fabric or the like in which fibrous thermoplastic resin is formed into a sheet shape. The reinforcing member is often in the form of a sheet that is placed along the mold when foam molding of the cushion pad is performed using the mold.

On the other hand, when foam molding a cushion pad using a mold, a reinforcing member formed into a three-dimensional shape may be used. For example, in the method for manufacturing a nonwoven fabric molded body described in Patent Document 1, a fabric sheet made of nonwoven fabric is molded into a nonwoven fabric molded body using a mold. In this method for manufacturing a nonwoven fabric molded body, a fabric sheet made of nonwoven fabric is heated, and then incisions are made in the molding surface of the heated fabric sheet, and the fabric sheet is molded into a three-dimensional shape using the mold.

JP 2015-16036 A

However, in the manufacturing method of the nonwoven fabric molded body of Patent Document 1, the process of heating the dough sheet and the process of molding the dough sheet into a three-dimensional shape are carried out separately. Therefore, there are many work steps to mold the nonwoven fabric molded body, and the management of the work steps is cumbersome. Therefore, further ingenuity is required to form a reinforcing member such as a nonwoven fabric molded body having a three-dimensional shape with fewer work steps.

The present invention was made in consideration of these problems, and aims to provide a method for manufacturing a reinforcing member and a method for manufacturing a cushion body using a reinforcing member that can reduce the number of work steps required to form a three-dimensional reinforcing member and simplify the management of the work steps.

One aspect of the present invention is
A manufacturing method for forming a reinforcing member to be integrated into a rear surface of a cushion pad from a sheet-like material into a three-dimensional shape, comprising the steps of:
A molding die having an upper mold portion and a lower mold portion, at least one of the upper mold portion and the lower mold portion having a built-in heater is used,
A preparation step of preparing the sheet-like material having a shape corresponding to the developed shape of the back surface of the cushion pad;
a placement step of placing the sheet material on the upper mold portion or the lower mold portion;
a forming step of sandwiching the sheet material between the upper mold part and the lower mold part of the mold heated by the heater and deforming at least a part of the sheet material to form the reinforcing member having a three-dimensional shape ,
A magnet is provided on a molding surface of the upper mold part or a molding surface of the lower mold part of the mold,
In the positioning step, the method for manufacturing a reinforcing member includes positioning the sheet-like material on the molding surface on which the magnet is provided by attracting a magnetic body provided on the sheet-like material to the magnet .

Another aspect of the present invention is
A method for manufacturing a cushion body using the reinforcing member having a three-dimensional shape manufactured by the method for manufacturing a reinforcing member, comprising the steps of:
A cushion body molding die having an upper mold part and a lower mold part is used,
a placement step of placing the reinforcing member on the upper mold part that is opened relative to the lower mold part;
an injection step of injecting a foaming raw material constituting a cushion pad into the lower mold part;
and a molding process of closing the upper mold part against the lower mold part, and foaming the foaming raw material in a cavity formed by the upper mold part and the lower mold part, to form the cushion pad having the reinforcing member integrated on its back surface.

(Method of manufacturing reinforcing member)
In the method for manufacturing a reinforcing member according to the above aspect, a mold is used in which a heater is built into at least one of the upper and lower mold parts. In the forming step, a sheet-like material is sandwiched between the upper and lower mold parts of the mold heated by the heater. At this time, a part of the sheet-like material is deformed by the heat of the mold, and a reinforcing member having a three-dimensional shape is formed.

With this configuration, the sheet-like material can be heated by the mold used in the forming step of forming the sheet-like material. Therefore, according to the manufacturing method of the reinforcing member of the one embodiment, the number of work steps for forming a reinforcing member having a three-dimensional shape can be reduced, and the management of the work steps can be simplified. In the manufacturing method of the reinforcing member of the one embodiment, a magnet is provided on the molding surface of the upper mold part or the molding surface of the lower mold part of the mold. Then, in the arrangement step, the magnetic body provided on the sheet-like material is attracted to the magnet, thereby arranging the sheet-like material on the molding surface on which the magnet is provided. With this configuration, it is possible to make it difficult for the sheet-like material arranged on the molding surface of the mold to shift position.

(Method of manufacturing the cushion body)
In the method for manufacturing a cushion body of the other aspect, a three-dimensional reinforcing member manufactured by the method for manufacturing a reinforcing member of the one aspect is used. In the positioning step, the reinforcing member can be easily positioned at a desired position on the upper mold part. In the molding step, the cushion pad with the reinforcing member arranged thereon is molded, so that the reinforcing member is arranged at a desired position on the back surface of the cushion pad while suppressing the occurrence of wrinkles, and a cushion body in which the reinforcing member is integrated along the back surface shape of the cushion pad can be manufactured.

1 is an explanatory diagram showing a cushion body according to a first embodiment, in which a reinforcing member is integrated into a rear surface of a cushion pad, as viewed from the rear side. FIG. FIG. 4 is an explanatory diagram showing the reinforcing member according to the first embodiment as viewed from the back side. FIG. 2 is an explanatory perspective view showing a molding die having an upper die portion, a lower die portion, and a sliding die portion according to the first embodiment. FIG. 4 is an explanatory diagram showing a molding die having an upper die portion, a lower die portion, and a sliding die portion according to the first embodiment, in a cross section corresponding to the cross section IV-IV in FIG. FIG. 4 is an explanatory diagram showing a molding die having an upper die portion, a lower die portion and a sliding die portion according to the first embodiment, in a cross section corresponding to the V-V cross section in FIG. FIG. 2 is an explanatory diagram showing a sheet material constituting a reinforcing member according to the first embodiment. FIG. 4 is an explanatory diagram showing a state in which a plurality of sheet materials are cut out from an original roll according to the first embodiment. FIG. 8 is an explanatory diagram showing, in an enlarged scale, the portion enclosed by the frame VIII in FIG. 4 , illustrating a state in which a magnetic body of a sheet-shaped material is attracted to a magnet provided in a forming die according to the first embodiment. FIG. 4 is an explanatory diagram showing a state in which a joint is formed on a sheet material according to the first embodiment. FIG. 11 is an explanatory diagram showing a state in which another joint is formed on the sheet material according to the first embodiment. FIG. 11 is an explanatory diagram showing a cushion body molding die having an upper mold part and a lower mold part according to a second embodiment, in a cross section taken along the left-right direction. FIG. 11 is an explanatory diagram showing a cushion body molding die having an upper mold part and a lower mold part according to a second embodiment, in a cross section taken along the vertical direction.

A preferred embodiment of the method for producing the reinforcing member and the method for producing a cushion body using the reinforcing member will now be described.
In the method for producing a reinforcing member according to the above aspect, the molding die may further include a slide die part that is slidable in a direction intersecting a direction in which the upper die part and the lower die part are opened and closed, which makes it easy to form a reinforcing member having a complex shape, such as a so-called undercut shape.

In addition, in the forming process, the heater may be used to raise the surface temperature of the forming surface of the mold above the softening point of the sheet-like material. This configuration makes it easier to quickly soften and deform at least a portion of the sheet-like material.

After the forming process, a cutting process may be performed in which a portion of the reinforcing member is cut out to form a product shape for integration with the rear surface of the cushion pad. This configuration allows the external shape of the reinforcing member to be adjusted.

In addition, in the forming process, a joint may be formed in which a portion of the sheet material overlaps and is joined to the reinforcing member. This configuration can prevent wrinkles from forming in the reinforcing member.

In the forming process, the sheet-like material may be provided with slits. This configuration allows the reinforcing member to be formed three-dimensionally with a good appearance.

A preferred embodiment of the method for manufacturing the reinforcing member and the method for manufacturing a cushion body using the reinforcing member will be described with reference to the drawings.
<Embodiment 1>
1 and 2, the manufacturing method of the reinforcing member 3 in this embodiment is to form the reinforcing member 3, which is to be integrated with the rear surface 201 of the cushion pad 2, into a three-dimensional shape from a sheet-like material 30. In the manufacturing method of the reinforcing member 3, as shown in FIGS. 3 to 5, a forming die 4 having an upper die portion 41 and a lower die portion 42 with heaters 44 built in the upper die portion 41 and the lower die portion 42 is used to carry out a preparation step, a placement step, and a formation step.

In the preparation process, as shown in Figures 6 and 7, a sheet-like material 30 is prepared in a shape corresponding to the unfolded shape of the back surface 201 of the cushion pad 2. In the placement process, as shown in Figure 8, the sheet-like material 30 is placed in the lower mold portion 42. In the formation process, as shown in Figures 4 and 5, the sheet-like material 30 is sandwiched between the upper mold portion 41 and the lower mold portion 42 of the molding die 4 heated by a heater 44, and at least a portion of the sheet-like material 30 is deformed to form a reinforcing member 3 with a three-dimensional shape.

A method for manufacturing the reinforcing member 3 of this embodiment will be described in detail below.
(Reinforcing member 3 and cushion body 1)
As shown in Fig. 1 and Fig. 2, the reinforcing member 3 is disposed on the back surface 201 of the cushion pad 2 to constitute the cushion body 1. Fig. 1 shows the cushion body 1 as viewed from the back side, and Fig. 2 shows the reinforcing member 3 as viewed from the back side. In Fig. 1 and Fig. 2, the upper side is indicated by reference character H1, and the lower side is indicated by reference character H2. The back side is indicated by reference character D1, and the front side is indicated by reference character D2. The cushion body 1 can be used to constitute a vehicle seat or the like. The reinforcing member 3 is constituted by a nonwoven fabric or the like in which a fibrous thermoplastic resin is formed into a sheet shape. The reinforcing member 3 is used to reduce the generation of abnormal noise when the cushion body 1 is disposed on a framework such as a seat frame, by contacting the framework.

The cushion body 1 of this embodiment constitutes the backrest of a vehicle seat. The cushion pad 2 of the cushion body 1 has a main body 21 and folded-back portions 221 formed by folding back an upper portion 211 and left and right side portions 212 of the main body 21 to the reverse side. A bag-shaped portion 22 is formed in the upper portion 211 and left and right side portions 212 of the cushion pad 2 to which the folded-back portions 221 are connected. The reverse side of the main body 21 of the cushion pad 2 is located on the rear side in the front-rear direction of the vehicle.

The rear surface 201 of the cushion pad 2 includes the rear surface 201 of the main body 21 as well as the inner surface as the rear surface 201 of the bag-shaped portion 22 (folded portion 221). The reinforcing member 3 is disposed on almost the entire rear surface 201 of the cushion pad 2. The reinforcing member 3 has a shape that conforms to the shape of the rear surface 201 of the cushion pad 2. The reinforcing member 3 has a main body portion 31 disposed on the rear surface 201 of the main body portion 21 of the cushion pad 2, and a bag-shaped portion 32 disposed on the rear surface 201 of the bag-shaped portion 22 of the cushion pad 2. The bag-shaped portion 32 has a shape in which the upper portion 311 and the left and right side portions 312 of the main body portion 31 are connected to the folded portions 321 that are formed by folding back the upper portion 311 and the left and right side portions 312 to the rear side.

The main body 31 of the reinforcing member 3 has multiple deformation openings 341 formed in an elongated shape along the vertical direction to facilitate bending of the cushion body 1. In addition, one side of the reinforcing member 3 also has an airbag opening 342 formed to facilitate the airbag placed in the seat being able to exit the seat when activated.

As shown in Figures 2 and 6, the reinforcing member 3 is formed by three-dimensionally deforming and partially bonding sheet-like material 30. The sheet-like material 30 has a portion where a slit 331 is provided at a position where a mountain-shaped folded portion 33 is to be formed. As shown in Figure 10, the slit 331 is provided in order to form the folded portion 33 in which portions of the sheet-like material 30 located on both sides of the slit 331 are overlapped and bonded at least twice. The slit 331 allows the sheet-like material 30 to be folded three-dimensionally in an attractive manner.

As shown in Figures 6 and 7, the sheet-like material 30 used in the manufacturing method of the reinforcing member 3 is formed into a predetermined sheet shape by a preparation step performed before the placement step. The sheet-like material 30 placed in the mold 4 in the placement step is cut out from a long original roll 300 in the preparation step into a predetermined sheet shape that is close to the unfolded shape of the reinforcing member 3. The sheet-like material 30 cut out from the original roll 300 has openings 341 for deformation, openings 342 for airbags, holes 343 for inserting a headrest, slits 331, etc. formed therein.

The sheet material 30 used in the placement process is cut into a predetermined sheet shape, so that multiple sheet materials 30 can be cut out side-by-side and adjacent to each other in the original roll 300. This configuration reduces the portion of the original roll of sheet material 30 that is unused and discarded, improving the yield of sheet material 30.

The fibrous thermoplastic resin that constitutes the sheet-like material 30 has a softening point of 100°C or less so that it can be quickly softened by the molding die 4. The heater 44 in the molding die 4 is configured to heat the sheet-like material 30 to a temperature equal to or higher than the softening point. The softening point is the temperature at which a material such as a thermoplastic resin begins to deform or soften when heated. In other words, the softening point, also called the softening temperature, indicates the temperature at which the material changes from a hard state to a soft, plastically deformable state.

As shown in FIG. 8, magnetic bodies 36 are provided on the edges of appropriate locations of the sheet-like material 30 to facilitate positioning along the molding surface 401 of the mold 4. The magnetic bodies 36 are attracted to magnets 45 provided on the molding surface 401 of the mold 4 and are used to hold the sheet-like material 30 in position relative to the mold 4. Examples of the magnetic bodies 36 that can be used include staples such as staplers, iron powder tape, and magnets.

(Molding mold 4)
3 to 5, the molding die 4 for forming the reinforcing member 3 into a three-dimensional shape is composed of an upper die portion 41, a lower die portion 42, and a slide die portion 43. The molding die 4 is configured to form the reinforcing member 3 in a state in which the front side surface 302 of the main body portion 31 faces upward. The upper die portion 41 is configured to press down the front side surface 302 of the reinforcing member 3, and the lower die portion 42 is configured to support the back side surface 301 of the reinforcing member 3. The slide die portion 43 is formed in three parts so as to press down the top portion 311 and the left and right side portions 312 of the reinforcing member 3 while being fitted laterally to the upper die portion 41 and the lower die portion 42.

The molding surface 401 of the lower mold part 42 is formed in a shape that follows the three-dimensional shape of the reinforcing member 3. As shown in Figures 3 to 5 and 8, at a position of the lower mold part 42 corresponding to the bag-shaped part 32 (folded part 321), a protruding part 421 is formed in which the upper surface protrudes upward and protrudes outward from the center part of the lower mold part 42.

The portion of the sheet material 30 in this embodiment where the bag-shaped portion 32 (folded portion 321) is formed is disposed on the molding surface 401 of the raised portion 421 of the lower mold portion 42. The molding surface 401 of the raised portion 421 is provided with a magnet 45 for attracting the magnetic body 36 of the sheet material 30. The magnet 45 in this embodiment is embedded in the raised portion 421 with a portion of its surface exposed to the molding surface 401. In other words, a portion of the molding surface 401 of the raised portion 421 is formed by the surface of the magnet 45.

The magnets 45 are distributed and positioned at multiple locations on the molding surface 401 of the raised portion 421. The magnets 45 are also provided on the molding surface 401 of the raised portion 421 in correspondence with the positions of the magnetic bodies 36 on the edge of the sheet-like material 30. The magnetic bodies 36 of the sheet-like material 30 are attracted to the multiple magnets 45 of the raised portion 421 of the lower mold portion 42, so that the sheet-like material 30 can be stably positioned at the target position on the lower mold portion 42 in a state that is unlikely to shift position.

As shown in FIG. 3, the molding surface 401 of the upper mold part 41 is formed in a shape that faces the molding surface 401 of the lower mold part 42 and sandwiches the sheet-like material 30. The slide mold part 43 is slidable in a direction that intersects (in this embodiment, perpendicular to) the opening and closing direction K of the upper mold part 41 and the lower mold part 42. The three slide mold parts 43 sandwich the sheet-like material 30 between the lower mold part 42 or the upper mold part 41, thereby forming a bag-shaped part 32 in the sheet-like material 30. The bag-shaped part 32 forms a so-called undercut shape, and can be formed and released by using the slide mold part 43.

As shown in Figures 2, 4, and 5, the slide mold portion 43 that presses down the upper portion of the reinforcing member 3 mainly forms the folded portion 321 of the upper portion 311 of the reinforcing member 3. The pair of slide mold portions 43 that press down the left and right side portions 312 of the reinforcing member 3 mainly form the folded portion 321 of the left and right side portions 312 of the reinforcing member 3.

The heater 44 in this embodiment is embedded in each of the upper mold part 41, the lower mold part 42, and the slide mold part 43. The heater 44 may be embedded in a position close to the molding surface 401 in the upper mold part 41, the lower mold part 42, and the slide mold part 43. The heater 44 in this embodiment is composed of hot water piping through which hot water used in factories flows. Note that, instead of using hot water piping, the heater 44 may be an electric heater or a plate heater that generates heat by electricity, or an oil heater that uses heated oil as a heat medium. By embedding the heater 44 in the molding die 4 as in this embodiment, the space required to install the device can be reduced compared to when a heating device is provided separately from the molding die 4.

(Details of Manufacturing Method of Reinforcement Member 3)
When forming the sheet material 30 into the three-dimensional reinforcing member 3, a preparation step, an arrangement step, and a formation step are performed. As shown in Fig. 6 and Fig. 7, in the preparation step, a long raw material 300 is pressed (cut out) to form a plurality of sheet materials 30. As shown in Fig. 3 and Fig. 8, in the arrangement step, the sheet material 30 is arranged on the lower mold section 42. At this time, the plurality of magnetic bodies 36 in the sheet material 30 are attracted to the plurality of magnets 45 in the raised portion 421, thereby fixing the sheet material 30 to the lower mold section 42.

In the placement process, the portion of the sheet-like material 30 where the bag-shaped portion 32 (folded portion 321) is to be formed is placed on the raised portion 421 by folding it to match the shape of the raised portion 421 of the lower mold portion 42. As shown in Figures 2 and 9, the sheet-like material 30 has a portion where a joint 37 is to be formed near the corners 313 between the upper portion 311 and the left and right side portions 312. The portion where the joint 37 is to be formed is placed on the raised portion 421 by folding a portion of the sheet-like material 30 so that it overlaps three or more times. The joint 37 makes it possible to form the reinforcing member 3 into the desired shape from the sheet-like material 30 in the subsequent formation process while suppressing the occurrence of wrinkles in the reinforcing member 3.

As shown in FIG. 2, when the sheet-like material 30 is arranged three-dimensionally on the raised portion 421, a portion in which a slit 331 is provided as a cut is set near the lower portion of one side portion 312. The portion in which the slit 331 is provided is arranged on the raised portion 421 by folding the portions of the sheet-like material 30 located on both sides of the slit 331 so as to overlap by more than double.

In the placement process, the upper mold part 41, the lower mold part 42, and the slide mold part 43 are each heated by a heater 44 embedded in the upper mold part 41, the lower mold part 42, and the slide mold part 43. In this embodiment, while the placement process and the formation process are being performed, hot water is constantly flowing through the hot water pipe that constitutes the heater 44, and each of the upper mold part 41, the lower mold part 42, and the slide mold part 43 is constantly heated.

In particular, during the forming process, the heater 44 heats the surface temperatures of the molding surfaces 401 of the upper mold portion 41, the lower mold portion 42, and the slide mold portion 43 to be higher than the softening point of the sheet material 30. The softening point of the sheet material 30 is in the range of 70°C or higher and lower than 100°C, and the heater 44 in this embodiment heats the upper mold portion 41, the lower mold portion 42, and the slide mold portion 43 to 100°C.

As shown in Figures 4 and 5, in the forming process, after the sheet-like material 30 is placed on the lower mold part 42, the multiple slide mold parts 43 are closed on the lower mold part 42, and the upper mold part 41 is closed on the lower mold part 42 and the multiple slide mold parts 43. Then, the sheet-like material 30 is sandwiched between the upper mold part 41, the lower mold part 42, and the multiple slide mold parts 43. Depending on the shape of the reinforcing member 3 to be manufactured, after the sheet-like material 30 is placed on the lower mold part 42, the upper mold part 41 may be closed on the lower mold part 42, and the multiple slide mold parts 43 may be closed on the lower mold part 42 and the upper mold part 41.

In the forming process, the sheet material 30 is sandwiched between the heated upper mold part 41, lower mold part 42, and multiple slide mold parts 43, and the sheet material 30 is softened by the heat transmitted from the upper mold part 41, lower mold part 42, and multiple slide mold parts 43. When the sheet material 30 has softened, it is in a moderately molten state.

The softened sheet material 30 is then deformed along the respective forming surfaces 401 of the upper mold portion 41, the lower mold portion 42, and the multiple slide mold portions 43, and is press-molded by the respective forming surfaces 401. At this time, as shown in FIG. 2, near the corners 313 between the upper portion 311 and the left and right side portions 312 in the bag-shaped portion 32 of the sheet material 30, a joint portion 37 is formed in which a portion of the sheet material 30 is joined in a triple or more overlapping manner, as shown in FIG. 9. Also, at this time, as shown in FIG. 2, near the lower portion of one side portion 312 of the sheet material 30, a joint portion 38 is formed in which portions of the sheet material 30 located on both sides of the slit 331 are joined in a double or more overlapping manner, as shown in FIG. 10.

Next, in the forming process, the sheet material 30 is held between the upper mold portion 41, the lower mold portion 42, and the multiple slide mold portions 43 for a predetermined period of time. This forms a three-dimensional reinforcing member 3 from the sheet material 30. After that, the upper mold portion 41 and the multiple slide mold portions 43 open (retract) relative to the lower mold portion 42, and the reinforcing member 3 is removed from the lower mold portion 42.

(Action and Effect)
In the manufacturing method of the reinforcing member 3 of this embodiment, a molding die 4 is used in which heaters 44 are built into the upper die portion 41, the lower die portion 42, and the plurality of slide die portions 43. Then, in the forming step, the sheet-like material 30 is sandwiched between the upper die portion 41, the lower die portion 42, and the plurality of slide die portions 43 heated by the heater 44. At this time, a part of the sheet-like material 30 is melted and joined by the heat of the upper die portion 41, the lower die portion 42, and the plurality of slide die portions 43, and the reinforcing member 3 having a three-dimensional shape is formed.

With this configuration, the sheet-like material 30 can be heated by the molding die 4 used in the forming process of forming the sheet-like material 30. Therefore, according to this embodiment of the manufacturing method for the reinforcing member 3, the number of work steps required to form the reinforcing member 3 with a three-dimensional shape can be reduced, and the management of the work steps can be simplified.

<Embodiment 2>
This embodiment describes a manufacturing method for a cushion body 1 using a three-dimensional reinforcing member 3 manufactured by a manufacturing method for the reinforcing member 3. In the manufacturing method for the cushion body 1, a placement step, an injection step, and a molding step are performed to mold the cushion body 1 in which the reinforcing member 3 is integrated with the back surface 201 of the cushion pad 2. In the manufacturing method for the cushion body 1, the cushion pad 2 is foam-molded so as to integrate the three-dimensional reinforcing member 3 with the back surface 201.

As shown in Figures 11 and 12, in the manufacturing method of the cushion body 1, a cushion body molding die 5 having an upper mold part 51 and a lower mold part 52 for molding the cushion body 1 is used. The upper mold part 51 is configured to mold the back side surface 201 of the cushion pad 2 on which the reinforcing member 3 is arranged, and the lower mold part 52 is configured to mold the front side surface of the cushion pad 2.

In the placement step, the reinforcing member 3 is placed in the upper mold part 51 that is opened relative to the lower mold part 52. At this time, since the reinforcing member 3 is formed in a three-dimensional shape, the reinforcing member 3 can be easily placed at the desired position in the upper mold part 51. Next, in the injection step, the foaming raw material 20 that constitutes the cushion pad 2 is injected into the lower mold part 52. The foaming raw material 20 is a liquid thermoplastic resin raw material that contains a foaming agent.

Next, in the molding process, the upper mold part 51 is closed relative to the lower mold part 52. Then, in the cavity 53 formed by the upper mold part 51 and the lower mold part 52, the foaming raw material 20 foams and flows between the lower mold part 52 and the reinforcing member 3, and the foaming raw material 20 fills the cavity 53. As a result, in the cavity 53, the cushion pad 2 with the reinforcing member 3 integrated into the back surface 201 is molded, and the cushion body 1 having the cushion pad 2 and the reinforcing member 3 is manufactured. After that, the upper mold part 51 is opened relative to the lower mold part 52, and the manufactured cushion body 1 is removed from the upper mold part 41.

In the manufacturing method of the cushion body 1 of this embodiment, a three-dimensional reinforcing member 3 manufactured by the manufacturing method of the reinforcing member 3 is used. Then, in the arrangement step, the reinforcing member 3 can be easily arranged at the desired position on the upper mold part 51. Also, in the molding step, the cushion pad 2 with the reinforcing member 3 arranged thereon is molded, and the reinforcing member 3 of the desired shape is arranged at the desired position on the back surface 201 of the cushion pad 2. Therefore, the occurrence of wrinkles in the reinforcing member 3 is suppressed even during molding of the cushion pad 2, and a cushion body 1 can be manufactured that has a reinforcing member 3 that is integrated without wrinkles along the shape of the back surface 201 of the cushion pad 2.

The reinforcing member 3 in this embodiment is the same as that shown in embodiment 1. Also, in this embodiment, components indicated by the same reference numerals as those in embodiment 1 are the same as those in embodiment 1.

<Other embodiments>
The reinforcing member 3 having a three-dimensional shape may have unnecessary ends cut off after being formed in the manufacturing method of the reinforcing member 3. More specifically, after the forming step in the manufacturing method of the reinforcing member 3, a cutting step may be performed in which a part of the reinforcing member 3 having a three-dimensional shape is cut off to form the reinforcing member 3 into a product shape for integration with the back side surface 201 of the cushion pad 2.

In this case, the external shape of the reinforcing member 3 can be adjusted by cutting out a portion of the reinforcing member 3. In addition, in this case, when preparing the sheet-like material 30, the sheet-like material 30 may be formed in a rough shape, which makes it easier to prepare the sheet-like material 30.

In addition, if the reinforcing member 3 does not have a bag-shaped portion 32 or if the reinforcing member 3 has a simple shape, the slide mold portion 43 is not necessary, and the molding die 4 may be composed of an upper mold portion 41 and a lower mold portion 42. For example, when manufacturing the reinforcing member 3 of the cushion body 1 that constitutes the seating portion of the seat, the slide mold portion 43 may not be necessary.

The present invention is not limited to the embodiments, and further different embodiments can be constructed without departing from the spirit of the invention. The present invention also includes various modifications, modifications within the scope of equivalents, etc.

REFERENCE SIGNS LIST 1 cushion body 2 cushion pad 20 foaming raw material 201 back side 21 main body 22 bag-shaped portion 221 folded portion 3 reinforcing member 30 sheet-like material 31 main body 32 bag-shaped portion 321 folded portion 33 folded portion 331 slit 36 magnetic body 37, 38 joint 4 molding die 401 molding surface 41 upper die portion 42 lower die portion 421 raised portion 43 slide die portion 44 heater 45 magnet 5 cushion body molding die 51 upper die portion 52 lower die portion 53 cavity

Claims (7)

A manufacturing method for forming a reinforcing member to be integrated into a rear surface of a cushion pad from a sheet-like material into a three-dimensional shape, comprising the steps of:
A molding die having an upper mold portion and a lower mold portion, at least one of the upper mold portion and the lower mold portion having a built-in heater is used,
A preparation step of preparing the sheet-like material having a shape corresponding to the developed shape of the back surface of the cushion pad;
a placement step of placing the sheet material on the upper mold portion or the lower mold portion;
a forming step of sandwiching the sheet material between the upper mold part and the lower mold part of the mold heated by the heater and deforming at least a part of the sheet material to form the reinforcing member having a three-dimensional shape ,
A magnet is provided on a molding surface of the upper mold part or a molding surface of the lower mold part of the mold,
In the placing process, a magnetic body provided on the sheet-like material is attracted to the magnet, thereby placing the sheet-like material on the molding surface on which the magnet is provided. This is a method for manufacturing a reinforcing member. The method for manufacturing a reinforcing member according to claim 1, wherein the molding die further has a slide die part that is slidable in a direction intersecting the opening and closing direction of the upper die part and the lower die part. The method for manufacturing a reinforcing member according to claim 1 or 2, wherein in the forming process, the heater raises the surface temperature of the forming surface of the mold above the softening point of the sheet-like material. The method for manufacturing a reinforcing member according to any one of claims 1 to 3, further comprising a cutting step of cutting out a part of the reinforcing member to form it into a product shape for integration with the back surface of the cushion pad, after the forming step. The method for manufacturing a reinforcing member according to any one of claims 1 to 4, wherein in the forming step, a joint is formed in the reinforcing member by overlapping and joining a portion of the sheet-like material. The method for manufacturing a reinforcing member according to any one of claims 1 to 5, wherein the forming step uses the sheet-like material with slits. A method for manufacturing a cushion body using a three-dimensional reinforcing member manufactured by the method for manufacturing a reinforcing member according to any one of claims 1 to 6 , comprising the steps of:
A cushion body molding die having an upper mold part and a lower mold part is used,
a placement step of placing the reinforcing member on the upper mold part that is opened relative to the lower mold part;
an injection step of injecting a foaming raw material constituting a cushion pad into the lower mold part;
and a molding process of closing the upper mold part against the lower mold part, and foaming the foaming raw material in a cavity formed by the upper mold part and the lower mold part, to form the cushion pad having the reinforcing member integrated on its back surface.

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