Seat cushion body

Abstract

To provide a seat cushion body that is less likely to lose cushion property even when a seat pad is bonded to a seat cover.SOLUTION: A seat cushion body 1 includes: a seat pad 2 which is made of a foaming resin; and a seat cover 3 with which the seat pad 2 is foamed and molded integrally so as to cover a surface of the seat pad 2. The seat cushion body 1 has a curved part 3C for forming a recess C1 on a seat inner side and a bulge C2 on a seat outer side in a frame part 3B constituting a seat peripheral lateral part of the seat cover 3.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a seat cushion body, and more particularly to a seat cushion body having a seat pad made of foamed resin and a seat cover formed integrally with the seat pad by foam molding so as to cover the surface of the seat pad. [Background technology]

[0002] Patent Document 1 discloses a seat cushion body in which a seat cover is set in a urethane foaming mold, and a seat pad is foam-molded integrally with the seat cover. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2022-137987 A Summary of the Invention [Problem to be solved by the invention]

[0004] In such a seat cushion body, the seat surface portion is likely to become hard because the seat pad is adhered to the seat cover. Therefore, the present invention provides a seat cushion body whose cushioning properties are not easily impaired even when the seat pad is adhered to the seat cover. [Means for solving the problem]

[0005] As a means for solving the above problems, the seat cushion body of the present invention employs the following means.

[0006] That is, the first invention of the present invention is a seat cushion body having a seat pad made of foam resin and a seat cover which is foam-molded integrally with the seat pad so as to cover the surface of the seat pad, and the seat cushion body has a bent portion which forms a recess toward the inside of the seat and / or a bulge toward the outside of the seat in the gusset portion which forms the seat peripheral side portion of the seat cover. Here, the "bulge toward the outside of the seat" includes not only a bulge toward the outside of the seat from the general surface of the gusset portion, but also a bulge toward the outside of the seat from the recess.

[0007] According to the first aspect of the present invention, even if the seat pad is attached to the lining portion, the bent portion allows the lining portion to be easily deflected by a load applied from the seating surface side. As a result, even if the seat pad is attached to the seat cover, the cushioning properties of the seat cushion body are not easily impaired.

[0008] A second aspect of the present invention is the seat cushion body according to the first aspect of the present invention, wherein the gusset portion having the bent portion is a front gusset and / or an outer gusset of the seat cushion.

[0009] According to the second aspect of the present invention, by providing a bent portion in the front gusset of the seat cushion, it is possible to reduce the feeling of pressure on the back of the thighs of a seated occupant when the seated occupant stretches his / her legs forward to operate the accelerator pedal, etc. Also, by providing a bent portion in the outer gusset of the seat cushion, it is possible to reduce the feeling of pressure on the back of the thighs of a seated occupant when getting on and off the vehicle.

[0010] A third invention of the present invention is a seat cushion body according to the second invention, wherein the bent portion is formed so as to extend continuously along the peripheral side portion of the seat across the front and outer gussets.

[0011] According to the third aspect of the present invention, the cam portion can be more easily deflected in response to a load applied from the seating surface side.

[0012] A fourth invention of the present invention is a seat cushion body according to any one of the first to third inventions, wherein the bent portion is bellows-shaped in that a recess toward the inside of the seat, a bulge toward the outside of the seat, and a recess toward the inside of the seat are aligned in the thickness direction of the seat.

[0013] According to the fourth aspect of the present invention, the cam portion can be made to bend even more easily in response to a load applied from the seating surface side.

[0014] A fifth aspect of the present invention is a seat cushion body according to any one of the first to third aspects, wherein the seat cover is made of a single seamless piece of synthetic leather material.

[0015] According to the fifth aspect of the present invention, when the seat pad is foam-molded together with the seat cover, the seat cover can be appropriately vacuumed and set in the mold. In addition, since the seat cover has no seams, the foaming resin material does not seep into the seams of the seat cover when the seat pad is foam-molded. Therefore, the seat cushion body can be more appropriately molded. [Brief description of the drawings]

[0016] [Figure 1] 1 is a perspective view illustrating a schematic configuration of a seat cushion body according to a first embodiment. [Diagram 2] FIG. [Diagram 3] FIG. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. [Diagram 5] FIG. 11 is a process diagram for setting a seat cover in a mold. [Figure 6] FIG. 11 is a process diagram showing a process for molding a seat cover by clamping a molding die. [Figure 7] FIG. 13 is a process diagram showing how to open the mold and inject foaming resin raw material into the rear surface of the cover. [Figure 8] FIG. 11 is a process diagram showing a process for molding a seat pad by clamping a mold. [Figure 9]11 is a process diagram showing a process of opening the mold and removing the seat cushion body. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0018] First Embodiment (Schematic configuration of seat cushion body 1) First, the configuration of a seat cushion body (hereinafter, "cushion body") 1 according to a first embodiment of the present invention will be described with reference to Figures 1 to 9. In the following description, when directions such as front, back, up, down, left and right are indicated, they refer to the respective directions shown in each figure. In the following description, when no specific reference figure is indicated or when no reference figure has a corresponding reference symbol, any of Figures 1 to 9 will be appropriately referenced.

[0019] 1, a cushion body 1 according to this embodiment is applied to a seat cushion SC forming a seating portion of an automobile seat. The seat cushion SC has a cushion frame (not shown) forming its framework, and the cushion body 1 covering the cushion frame from above.

[0020] The cushion body 1 is composed of a seat pad 2 made of polyurethane resin foam and a seat cover 3 made of synthetic leather material made of polyvinyl chloride resin (PVC) that covers the surface of the seat pad 2. The seat cover 3 is made of a single seamless piece of synthetic leather material.

[0021] The seat cover 3 has a top plate portion 3A that covers the seating surface portion of the seat pad 2, and a gusset portion 3B that covers the seat peripheral side portion of the seat pad 2. The gusset portion 3B is composed of a front gusset B1 that covers the front side portion of the seat pad 2, an outer gusset B2 that covers the outer side portion, an inner gusset B3 that covers the inner side portion, and a rear gusset (not shown) that covers the rear side portion.

[0022] The seat cover 3 is configured such that the seat pad 2 is foamed and molded integrally with the back surface of the seat cover 3 by the so-called foam-in-skin method. Accordingly, the seat pad 2 is bonded integrally to the seat cover 3 over the entire back surface of the top plate portion 3A and the entire back surface of the seat cover portion 3B. Due to this bonding, the surface portion of the seat pad 2 facing the seat cover 3 is harder than the center portion.

[0023] However, the bent portion 3C is formed in the seat cover 3's flared portion 3B, which becomes hard due to the integral foaming, to make the flared portion 3B more flexible against the load applied from the seating surface side. As a result, the cushion body 1 is less likely to lose its cushioning properties even though the seat cover 3 and the seat pad 2 are integrally molded.

[0024] The bent portion 3C is formed so as to extend continuously across the front gusset B1, the outer gusset B2, and the inner gusset B3 (see Figs. 2 and 3). Hereinafter, the front gusset B1, the outer gusset B2, and the inner gusset B3 will be collectively described as the gusset portion 3B.

[0025] The bent portion 3C is configured to form an accordion-like bend extending along the peripheral side portion of the sheet with respect to the flared portion 3B. Specifically, as shown in Fig. 4, the bent portion 3C is configured to form a recess C1 that is bent so as to be recessed in a V-shape in cross section on the inside of the sheet with respect to the flared portion 3B, continuously at two positions in the sheet thickness direction.

[0026] Each recess C1 is formed in a middle region in the sheet thickness direction away from the upper and lower edges of the flared portion 3B. Each recess C1 is formed so as to be recessed from the general surface of the flared portion 3B toward the inside of the sheet. Each recess C1 forms a bulge C2 in the region between each recess C1 of the flared portion 3B, which bulges outward from each recess C1 in a V-shaped cross section.

[0027] The bellows-shaped bent portion 3C is formed in the flared portion 3B, so that the flared portion 3B is easily bent by a load applied from the seating surface side (the upper side in the figure). Specifically, the flared portion 3B is easily bent by the load applied from the seating surface side so as to crush the bellows of the bent portion 3C downward on the seat due to the support from the cushion frame (not shown).

[0028] Therefore, even if the thighs of a seated occupant are pressed against the outer top plate side of the seat cushion SC from above when getting on or off, the outer gusset B2 can be relatively flexibly bent, thereby reducing the pressure exerted on the backs of the thighs from the outer gusset B2.

[0029] In addition, when a seated occupant stretches his / her legs forward to operate the accelerator pedal, etc., even if the thighs are pressed against the front edge of the seat cushion SC from above, the front lining B1 can be bent relatively flexibly, thereby reducing the pressure exerted on the backs of the thighs by the front lining B1.

[0030] Furthermore, although the seat cover 3 has a flexible structure as described above, it is molded integrally with the seat pad 2, so that wrinkles are less likely to occur in the seatback portion 3B even if the passengers get on and off the seat or put their feet up as described above are repeated.

[0031] Next, a method of foam molding the seat pad 2 integrally with the seat cover 3 will be described. As shown in Fig. 5, first, the seat cover 3, which has been heated and softened in advance, is set on the lower molding die ML of the molding die M so that it is brought into close contact with the molding surface by vacuum drawing. At this time, since the seat cover 3 is made of a seamless single piece of synthetic leather material, the seat cover 3 can be brought into close contact with the molding surface of the lower molding die ML by appropriately vacuum drawing.

[0032] Next, as shown in Fig. 6, the cover forming upper die MC for forming the seat cover 3 is clamped to form the seat cover 3 into a shape that matches the forming surface of the forming lower die ML. After that, as shown in Fig. 7, the cover forming upper die MC is opened.

[0033] Next, the foaming resin raw material of the seat pad 2 is poured onto the cover back surface (upper surface in the figure) of the seat cover 3 left on the molding surface of the lower molding mold ML. Then, as shown in Fig. 8, the pad molding upper mold MP for molding the seat pad 2 is clamped, and the seat pad 2 is foam-molded integrally with the seat cover 3. At this time, since the seat cover 3 is made of a single seamless piece of synthetic leather material, the foaming resin raw material of the seat pad 2 does not seep into the seams, and the seat pad 2 can be properly molded integrally with the seat cover 3.

[0034] Thereafter, the pad forming upper die MP is opened, and the formed cushion body 1 is removed from the forming lower die ML, as shown in Fig. 9. Through the above steps, the seat pad 2 and the seat cover 3 can be integrally formed.

[0035] To sum up, the cushion body 1 according to this embodiment has the following configuration: In the following, the reference characters in parentheses correspond to the respective components shown in the above embodiment.

[0036] That is, the seat cushion body (1) has a seat pad (2) made of foamed resin, and a seat cover (3) which is foam-molded integrally with the seat pad (2) so as to cover the surface of the seat pad (2). The seat cushion body (1) has a bent portion (3C) which forms a recess (C1) toward the inside of the seat and / or a bulge (C2) toward the outside of the seat in a gusset portion (3B) which forms the side portion around the seat of the seat cover (3).

[0037] According to the above-mentioned configuration, even if the seat pad (2) is bonded to the flaps (3B), the bent portion (3C) makes it easy for the flaps (3B) to bend in response to a load applied from the seating surface side. As a result, even if the seat pad (2) is bonded to the seat cover (3), the cushioning properties of the seat cushion body (1) are not easily impaired.

[0038] Also, the seat cushion (3B) having the bent portion (3C) is the front seat cushion (B1) and / or the outer seat cushion (B2). According to the above configuration, the bent portion (3C) is provided in the front seat cushion (B1) of the seat cushion (SC), thereby reducing the sense of pressure on the back of the thighs of a seated occupant when the seated occupant stretches his / her legs forward to operate the accelerator pedal, etc. Also, the bent portion (3C) is provided in the outer seat cushion (B2) of the seat cushion (SC), thereby reducing the sense of pressure on the back of the thighs of a seated occupant when the seated occupant gets in and out of the seat.

[0039] In addition, the bent portion (3C) is formed so as to extend continuously along the peripheral side portion of the seat from the front gusset (B1) to the outer gusset (B2). According to the above-mentioned configuration, the gusset portion (3B) can be more easily deflected by the load applied from the seating surface side.

[0040] In addition, the bent portion (3C) is formed in a bellows shape in which a recess (C1) toward the inside of the seat, a bulge (C2) toward the outside of the seat, and another recess (C1) toward the inside of the seat are aligned in the thickness direction of the seat. With this configuration, the flared portion (3B) can be more easily deflected by a load applied from the seating surface side.

[0041] In addition, the seat cover (3) is made of a single seamless piece of synthetic leather material. With this configuration, when the seat pad (2) and the seat cover (3) are foam-molded together, the seat cover (3) can be set in the mold (M) by appropriately evacuating the seat cover (3). In addition, since the seat cover (3) has no seams, the foaming resin material does not seep into the seams of the seat cover (3) when the seat pad (2) is foam-molded. This allows the seat cushion body (1) to be molded more appropriately.

[0042] Other embodiments Although one embodiment of the present invention has been described above, the present invention can be embodied in various forms other than the above embodiment.

[0043] 1. The seat cushion body of the present invention may be applied to seats for vehicles other than automobiles, such as trains, as well as seats for vehicles other than vehicles, such as airplanes and ships. The seat cushion body may also be applied to seats other than vehicles, such as seats installed in various facilities, such as sports facilities, theaters, concert halls, and event halls, as well as massage seats.

[0044] 2. The bent portion formed in the seat cover may be formed in the seat back, i.e., the outer seat back and / or the inner seat back, in addition to the seat back of the seat cushion. The bent portion may be formed only in either the front seat back or the outer seat back of the seat cushion.

[0045] When the bent portions are formed on adjacent surfaces of the gusset portion (such as the front gusset and the outer gusset), the bent portions may be formed to extend continuously along each surface, or may be formed to extend intermittently. The bent portions may be formed so that one or more indentations toward the inside of the sheet and one or more bulges toward the outside of the sheet are arranged in the sheet thickness direction, or may be formed so that only one or more indentations or only one bulge are formed.

[0046] The bent portion may have depressions and / or bulges formed continuously in the thickness direction of the sheet, or may have depressions and / or bulges formed at intervals in the thickness direction of the sheet. The bent portion may have a V-shaped cross section that is bent so as to be concave or bulge, or may have a U-shaped cross section that is curved or folded. When a bulge toward the outside of the sheet is formed between the depressions in the bent portion, the bulge toward the outside of the sheet may be either one that bulges toward the outside of the sheet from the general surface of the gusset portion or one that does not bulge toward the outside of the sheet from the general surface.

[0047] 3. The seat cover may be made of synthetic leather material with seams, with multiple cover pieces sewn together into one. In that case, it is advisable to provide a separate sealant (film, etc.) on the back of the seat cover to prevent air leakage when the seat cover is vacuumed and set in the mold, and to prevent resin seepage when the foaming resin raw material is poured in and foamed together. The seat cover may be made of synthetic leather material made of polyvinyl chloride resin (PVC), synthetic leather material made of polyurethane resin (PU) or elastomer. [Explanation of symbols]

[0048] 1 Cushion body (cushion body for seat) 2 Seat pad 3 Seat covers 3A Top plate 3B Kamachi section B1 Front kamachi B2 Outakamachi B3 Innakamachi 3C Bending section C1 Dent C2 Bulge SC seat cushion M mold MC cover molding upper die MP Pad forming upper die ML lower mold

Claims

1. A seat cushion body having a seat pad made of a foamed resin and a seat cover which is foam-molded integrally with the seat pad so as to cover a surface of the seat pad, The seat cushion body has a bent portion that forms a recess toward the inside of the seat and / or a bulge toward the outside of the seat in a gusset portion that forms a side portion around the seat periphery of the seat cover.

2. The seat cushion body according to claim 1, The seat cushion body, wherein the gusset portion having the bent portion is a front gusset and / or an outer gusset of the seat cushion.

3. The seat cushion body according to claim 2, The bent portion is formed so as to extend continuously along the peripheral side portion of the seat across the front and outer gussets.

4. The seat cushion body according to any one of claims 1 to 3, The bent portion is bellows-shaped in that a recess toward the inside of the seat, a bulge toward the outside of the seat, and a recess toward the inside of the seat are aligned in the thickness direction of the seat.

5. The seat cushion body according to any one of claims 1 to 3, The seat cushion body is made of a seamless piece of synthetic leather material.

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