snap retainer

Abstract

Provided is a buckle holding member used when a seat cushion (20) is foam molded, the seat cushion (20) having a buckle (24) used for mounting a seat cover (18) to the seat cushion (20). A buckle holding unit (50) is provided to a lower mold (42) of a molding mold (40) to hold the buckle (24) at the time of foam molding. The buckle holding unit (50) has a hooking portion (54) sandwiched by a pair of hooking pieces (30) of the buckle (24), a base portion (55) extending from the lower mold (42) to the hooking portion (54), and a cornice portion (56) extending to the side from the base portion (55) as it goes from the lower side toward the upper side.

Description

[0001] This application is a divisional application of the application with the application number 202080010040.8, the application date of January 20, 2020, and the title of the buckle holding unit, the molding die, and the manufacturing method of the seat cushion. TECHNICAL FIELD

[0002] The present application relates to a buckle holding unit that holds a buckle when a seat cushion is molded, a molding die having the buckle holding unit, and a manufacturing method of a seat cushion using the buckle holding unit. BACKGROUND

[0003] A seat for a vehicle holds a seat cover by using a buckle provided at the bottom of a groove portion formed in one face of a seat cushion, guides a part of the seat cover into the groove portion, and installs the seat cover in an extended state (for example, refer to Patent Literature 1). Such a buckle has a pair of engagement claws arranged in opposition. An arrow-shaped installation tool installed in the seat cover is fitted between the pair of engagement claws, and the seat cover is held to the seat cushion.

[0004] As in Patent Literature 1, the aforementioned seat cushion is obtained by insert molding in which a foamed body material is foamed and solidified in a state in which the buckle is installed in a fixing member provided in a molding die and the buckle is arranged at a position corresponding to the bottom of the groove portion of the seat cushion.

[0005] PRIOR ART DOCUMENTS

[0006] PATENT LITERATURE

[0007] Patent Literature 1: Japanese Patent Application Publication No. 2017-60582 SUMMARY

[0008] PROBLEMS TO BE SOLVED BY THE INVENTION

[0009] The fixing member of Patent Literature 1 suppresses the foamed body material from entering between the pair of engagement claws by forming a wall surface that matches the shape of the engagement claws. However, if the wall surface of the fixing member is formed with high precision to match the shape of the engagement claws, a large force is required when the buckle is installed in the fixing member, which makes it difficult to install the buckle in the fixing member. In addition, if the engagement force of the fixing member and the buckle is too strong, the buckle does not easily come off from the fixing member when the seat cushion is demolded, and there is a risk that the buckle will fall off from the seat cushion.

[0010] The present application has been made in view of the aforementioned problems involved in the conventional technology, and has been made to appropriately solve these problems. An object of the present application is to provide a buckle holding unit that can easily attach and detach a buckle and can prevent a foamed body from adhering to an unnecessary portion, a molding die, and a manufacturing method of a seat cushion.

[0011] TECHNICAL SOLUTION FOR SOLVING THE PROBLEMS

[0012] According to an aspect of the present application, there is provided a buckle holding unit, which is a buckle holding unit used when a seat cushion is foamed, the seat cushion having a buckle used to mount a seat cover to the seat cushion, the buckle holding unit being provided to a lower mold of a molding mold to hold the buckle when foaming, the buckle holding unit having: a clamping portion clamped by a pair of clamping pieces of the buckle; a base portion extending from the lower mold to the clamping portion; and a eave portion extending from the base portion to a lateral direction as it goes upward from a lower direction.

[0013] Also, in the buckle holding unit, the clamping portion can have: a concave portion capable of receiving the clamping pieces and recessed toward the lateral direction; and a separation preventing portion preventing the clamping pieces from being separated and bulging toward the lateral direction, the eave portion can be provided to cross an imaginary area in the left-right direction as viewed in a direction in which the eave portion extends, the imaginary area being an area through which the concave portion passes when the concave portion is virtually moved downward.

[0014] Also, in the buckle holding unit, the eave portion can have both end portions crossing the left-right direction extending upward from the edge of the concave portion as viewed in a direction in which the eave portion extends.

[0015] Also, in the buckle holding unit, the eave portion can extend from a middle position between a lower end and an upper end of the base portion toward the lateral direction.

[0016] According to an aspect of the present application, there is provided a molding mold, which is a molding mold of a seat cushion provided with the buckle holding unit, the seat cushion having a groove portion provided to a surface thereof and in which a buckle is provided, the lower mold being provided with a groove forming portion forming the groove portion, and the groove forming portion being provided with a setting recess portion in which the buckle holding unit is installed.

[0017] According to an aspect of the present application, there is provided a method of manufacturing a seat cushion, the seat cushion having a buckle used to mount a seat cover, a molding mold being composed of a lower mold and an upper mold, the lower mold being provided with a buckle holding unit holding the buckle, the buckle being provided to the buckle holding unit, a foaming body material being supplied to the molding mold, the foaming body material being foamed by the buckle holding unit while being guided in a direction away from an assembly portion of the buckle holding unit and the buckle as the foaming body material is foamed to move upward from a lower direction, and the seat cushion being molded as the foaming body material is foamed.

[0018] Also, in the seat cushion manufacturing method described above, the buckle holding unit can have a clamping portion clamped by the pair of clamping pieces of the buckle, and a base portion extending from the lower mold to the clamping portion, and a gable portion can be provided on the base portion to extend to the side as it goes from the lower portion to the upper portion, and the gable portion can guide the foamed material toward a direction away from the assembly portion of the buckle holding unit and the buckle.

[0019] Also, in the seat cushion manufacturing method described above, the gable portion can extend to the side from a middle position between the lower end and the upper end of the base portion.

[0020] Effects of Invention

[0021] According to the buckle holding unit and the molding die of the present invention, the buckle can be easily assembled and disassembled, and the foamed material can be prevented from adhering to unnecessary portions.

[0022] According to the seat cushion manufacturing method of the present invention, the buckle can be easily assembled and disassembled, and the foamed material can be prevented from adhering to unnecessary portions. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 FIG. 1 is a perspective view showing a seat using a seat cushion according to an embodiment of the present invention.

[0024] Figure 2 FIG. 2 is a plan view showing the seat cushion of the embodiment. Also, it is shown from one surface side of the seat cushion.

[0025] Figure 3 FIG. 3 is a sectional view showing the installation of a seat cover to a buckle in the seat cushion of the embodiment.

[0026] Figure 4 FIG. 4 is a perspective view showing the buckle of the embodiment.

[0027] Figure 5 FIG. 5 is a plan view showing a lower mold of the molding die of the embodiment.

[0028] Figure 6 FIG. 6 is a perspective view showing a buckle holding member of the embodiment.

[0029] Figure 7 FIG. 7 is a perspective view showing a state where the buckle holding member of the embodiment is provided to the lower mold.

[0030] Figure 8 FIG. 8 is a plan view showing the buckle holding member of the embodiment.

[0031] Figure 9A FIG. 9 is a front view showing the buckle holding member of the embodiment, and shows a state before the buckle is installed.

[0032] Figure 9B is a front view of a buckle retainer of an embodiment, and shows a state after a buckle is attached.

[0033] Figure 10A is an explanatory view of a manufacturing process of a seat cushion of an embodiment, and shows a state where a buckle retainer is attached to a lower mold.

[0034] Figure 10B is an explanatory view of a manufacturing process of a seat cushion of an embodiment, and shows a state after a foaming material is injected.

[0035] Figure 11A shows a state immediately before a buckle is attached to a buckle retainer. Further, a cross section at a position corresponding to the A-A line of Figure 9B is shown.

[0036] Figure 11B shows a state where a buckle is attached to a buckle retainer. Further, a cross section at a position corresponding to the A-A line of Figure 9B is shown.

[0037] Figure 12 is a perspective view showing a modification of a buckle retainer.

[0038] Figure 13 is a cross-sectional view taken at a position corresponding to the B-B line of Figure 12 is shown. DETAILED DESCRIPTION

[0039] Next, a buckle retainer unit and a manufacturing method of a seat cushion to which the present application pertains will be described below with reference to the drawings, taking appropriate embodiments. Further, in the embodiments, a seat cushion 20 for a seat 10 provided in a passenger room of an automobile will be described.

[0040] EMBODIMENT

[0041] Figure 1 is a perspective view showing a seat 10 using a seat cushion 20 to which an embodiment of the present application pertains. As shown in Figure 1As shown, a vehicle seat 10 includes a seat portion 12 that supports the occupant's lower body; a backrest 14 that is tiltably disposed at the rear of the seat portion 12 and supports the occupant's upper body; and a headrest 16 disposed above the backrest 14 and supports the occupant's head. The seat portion 12 and backrest 14 are primarily formed of soft polyurethane foam (foam). They each include a cushioning seat pad 20 and a seat cover 18 made of cloth, synthetic leather, genuine leather, or the like, stretched to cover the entire seat pad 20. The seat portion 12 and backrest 14 have similar basic structures and are manufactured using the same methods. Therefore, the following description will focus on the seat pad 20 that forms the seat portion 12. In the following description of the seat pad 20, up, down, front, back, left, and right are defined based on the vehicle's installed state. The seat pad 20 constituting the seat portion 12 has an upper side, on which a seated passenger's support surface lies, and a lower side, on which a vehicle body lies.

[0042] Figure 2 It is a plan view showing the seat pad 20 . Figure 2 2 shows the upper surface of the seat pad 20. Figure 2 As shown, the seat pad 20 is provided with a plurality of grooves 22 that open on the upper surface that serves as the passenger side. The seat pad 20 of the embodiment is formed with two grooves 22, 22 extending in the front-rear direction and a groove 22 extending in the left-right direction between the two grooves 22, 22 extending in the front-rear direction.

[0043] Figure 3 2 is a cross-sectional view for explaining the installation of the seat cover 18 to the seat pad 20. Figure 2 and Figure 3 As shown, the locking piece 30 of the buckle 24 is provided on the seat pad 20 at the bottom of the groove 22 so as to protrude upward. With the arrow-shaped mounting tool 26 mounted on the seat cover 18 held by the buckle 24, the seat cover 18 is guided into the groove 22, thereby mounting the lower seat cover 18 to the seat pad 20 without wrinkles (with tension applied).

[0044] Figure 4 2 is a perspective view showing the buckle 24. Figure 4 As shown, the buckle 24 includes a plate-shaped base portion 28 embedded in the foam forming the seat cushion 20, and two pairs of locking tabs 30 extending upward (on one side of the seat cushion 20) from the base portion 28. The two pairs of locking tabs 30 are spaced apart in the direction in which the groove 22 extends. The pair of locking tabs 30 face each other in the width direction of the groove 22.

[0045] The locking piece 30 has a claw portion 30a formed so as to protrude toward the object side of the locking piece 30 at the front end thereof. In addition, the base portion 28 has a through-hole 28a at a position outside the position at which the locking piece 30 protrudes from the base portion 28. This through-hole 28a allows the flow of the foam material H (described later) when the seat cushion 20 is molded. Furthermore, the buckle 24 in this example is a molded product of synthetic resin that is integrally molded with the base portion 28 and the locking piece 30. Figure 11B

[0046] Furthermore, in the following description, the direction in which the groove walls of the groove portion 22 face each other is referred to as the width direction, and the direction in which the groove portion 22 extends is referred to as the lateral direction. In addition, the depth direction of the groove portion 22 is referred to as the up-down direction.

[0047] Next, the molding die 40 that molds the seat cushion 20 will be described. Figure 10A and Figure 10B are diagrams that show the manufacturing process of the seat cushion 20. As shown in Figure 10A , the molding die 40 is composed of a lower die 42 and an upper die 44 that is disposed on the upper side of the lower die 42 at the time of clamping. The molding die 40 can be changed to a clamped state in which a cavity 46 is formed between the lower die 42 and the upper die 44 (see Figure 10B ) and an unclamped state in which the inside of the molding die 40 can be accessed (see Figure 10A ) by rotating the upper die 44. The molding die 40 molds the seat cushion 20 upside down in the cavity 46. In other words, the molding die 40 is configured so as to mold the seat cushion 20 in a posture in which the buckle 24 is located on the lower side. The upper surface and the side surface of the seat cushion 20 are mainly molded by the lower die 42, and the lower surface of the seat cushion 20 is mainly molded by the upper die 44.

[0048] Figure 5 is a plan view that shows the lower die 42 of the molding die 40. As shown in Figure 5 , the lower die 42 has a projection portion 48 that protrudes upward from a lower die surface (mold surface) 42a that defines the upper surface of the seat cushion 20. The projection portion 48 defines the groove portion 22 of the seat cushion 20.

[0049] Figure 7 is a perspective view that shows a state in which the buckle holding member 50 is disposed on the lower die 42. As shown in Figure 7 , the lower die 42 is provided with a projection portion (groove forming portion) 48 that forms the groove portion 22. The projection portion 48 is provided with a setting recess 48a in which the buckle holding member (buckle holding unit) 50 is installed. The buckle holding member 50 in this example is detachably installed with respect to the lower die 42 by screwing. The lower die 42 molds the groove portion 22 by the projection portion 48 and the buckle holding member 50.

[0050] Figure 6 ​is a perspective view showing the buckle retainer 50. Figure 8 is a plan view showing the buckle retainer 50. Figure 9A and Figure 9B is a front view showing the buckle retainer 50. Figure 9A shows a state before the buckle is attached. Figure 9B is a state after the buckle is attached. As shown in Figure 6 , Figure 8 , Figure 9A and Figure 9B , the buckle retainer 50 is a block shape made of metal such as stainless steel, which is formed in correspondence with the shape of the groove portion 22. The buckle retainer 50 has side wall surfaces 51 extending in the vertical direction and the lateral direction. The side wall surfaces 51 cause the groove walls of the groove portion 22 to be molded when the seat cushion 20 is molded (refer to Figure 7 ).

[0051] The buckle retainer 50 has a recessed portion 52 and a retaining portion 54. The recessed portion 52 is formed by recessing the side wall surfaces 51 inwardly. The recessed portion 52 is a portion that can receive the retaining pieces 30 of the buckle 24. The retaining portion 54 is provided on the inner side of the recessed portion 52. The retaining portion 54 prevents the retaining pieces 30 received by the recessed portion 52 from coming off.

[0052] More specifically, the buckle retainer 50 is formed by recessing both side wall surfaces 51, 51 extending in the vertical direction and the lateral direction, and has a pair of recessed portions 52, 52 configured to be able to receive a pair of retaining pieces 30, 30. In addition, the buckle retainer 50 is provided between the pair of recessed portions 52, 52, and has a retaining portion 54 in which the pair of retaining pieces 30, 30 are fitted (refer to Figure 11A ).

[0053] Furthermore, the buckle retainer 50 has a eave portion 56. The eave portion 56 is provided to the side wall surfaces 51. The eave portion 56 projects from the side wall surfaces 51 as it goes from the lower side of the buckle retainer 50 toward the lower edge 52a of the recessed portion 52. The buckle retainer 50 of the present example has two sets of groups composed of the retaining portion 54 and the pair of recessed portions 52, 52 in correspondence with the pair of retaining pieces 30, 30.

[0054] As shown in Figure 6 , Figure 9A and Figure 9B , the recessed portion 52 is provided to a region of the side wall surface 51 from the upper end to a position halfway toward the lower side. The recessed portion 52 is a shape corresponding to the outer shape of the retaining piece 30. The lower edge 52a of the recessed portion 52, which projects outwardly in the width direction than the retaining portion 54, opposes the front end of the retaining piece 30 received by the recessed portion 52. In addition, the side edge 52b of the recessed portion 52, which projects outwardly in the width direction than the retaining portion 54, opposes the side edge of the retaining piece 30 received by the recessed portion 52 (refer to Figure 9B). A pair of recessed portions 52, 52 are arranged in a symmetrical positional relationship with the locking portion 54 interposed therebetween in the buckle holder 50. Further, the side edge 52b refers to an edge portion of the recessed portion 52 visible when the buckle holder 50 is viewed in the direction indicated by the arrow. Figure 9A

[0055] As shown in Figure 6 , the locking portion 54 is provided with an anti -disengagement portion 54a at a middle portion in the up-down direction, the anti -disengagement portion 54a being formed so as to project outward in the width direction as it goes from the upper end toward the lower side. The anti -disengagement portion 54a is provided on both sides in the width direction of the locking portion 54. When a pair of locking pieces 30, 30 are fitted into the locking portion 54, the buckle 24 is held to the locking portion 54 by the hooking of the anti -disengagement portion 54a with the claw portion 30a of the locking piece 30. If a pair of locking pieces 30, 30 are fitted into the locking portion 54, the base portion 28 is placed on the upper end of the buckle holder 50, whereby the buckle 24 is supported by the buckle holder 50 (see Figure 11B ). At this time, each locking piece 30 is covered by the lower edge 52a and both side edges 52b, 52b of the recessed portion 52 of the buckle holder 50, so the invasion of the foam material H between the locking piece 30 and the locking portion 54 is prevented (see Figure 9B ).

[0056] Figure 11A Figure 11B are explanatory diagrams showing the function of the buckle holder 50 in the manufacturing process of the seat cushion 20. Further, a cross section taken at a position corresponding to the A-A line of Figure 9B is shown. As shown in Figure 11A , the buckle holder 50 has a locking portion 54 sandwiched by a pair of locking pieces 30 of the buckle 24, a base portion 55 extending from the lower mold 42 to the locking portion 54, and a cornice portion 56 projecting laterally from the base portion 55 as it goes from the lower side toward the upper side. In other words, the cornice portion 56 projecting laterally from the base portion 55 is provided between the locking portion 54 and the lower mold 42.

[0057] Next, the manufacturing method of the seat cushion 20 by the molding mold 40 provided with the aforementioned buckle holder 50 will be described. First, the buckle 24 is installed to the buckle holder 50 provided to the lower mold 42 (see Figure 10A and Figure 11A ). Specifically, a pair of locking pieces 30, 30 of the buckle 24 are fitted into the locking portion 54. By this, the buckle 24 is held by the buckle holder 50 in a state where each locking piece 30 is housed in the corresponding recessed portion 52 and the base portion 28 is placed on the upper side of the buckle holder 50. In this state, the foam material H is supplied to the lower mold face 42a of the lower mold 42, the molding mold 40 is clamped, the foam material H is foamed / solidified in the cavity 46, and the seat cushion 20 is molded (see Figure 10B ). ​​

[0058] As shown in Fig. 1, the foamed material H supplied to the lower mold 42 is upwardly moved from the lower mold 42 as it foams. The foamed material H upwardly moved from the lower mold 42 is guided by the snap retainer 50 toward a direction away from the assembled portion of the snap retainer 50 and the snap 24 while being foamed, thereby forming the seat cushion 20. Figure 11B

[0059] Specifically, when the foamed material H is upwardly moved from the lower mold 42, the foamed material H is guided by the inclined surface 56a of the eave portion 56 away from the assembled portion of the snap retainer 50 and the snap 24. Therefore, the foamed material H does not directly flow into the recessed portion 52, but flows into the recessed portion 52 through a long path due to the eave portion 56.

[0060] Thus, by the eave portion 56 of the snap retainer 50, the timing at which the foamed material H reaches the recessed portion 52 is delayed. As a result, the foamed material H in a state where foaming / curing progresses and viscosity rises reaches the recessed portion 52, compared with the foamed material H which directly flows into the recessed portion 52 without the eave portion 56. The foamed material H in which foaming / curing progresses and viscosity is high is less likely to enter a small gap. As a result, the foamed material H is less likely to intrude into the inside of the locking piece 30 from the gap between the recessed portion 52 and the locking piece 30, and the foamed material is prevented from adhering to the inside of the locking piece 30 (unnecessary portion). Here, the inside of the locking piece 30 is the side of the locking piece 30 opposite to the locking portion 54, and is the side which engages with the mounting tool 26 when the mounting tool 26 is mounted with the seat cover 18.

[0061] However, it is preferable that the locking portion 54a of the snap retainer 50 and the claw portion 30a of the locking piece 30 of the snap 24 are engaged with each other by the smallest possible engagement force. Thus, the snap retainer 50 and the snap 24 can be attached and detached by a small force. In the present example, the snap retainer 50 can attach the snap 24 by a small force, and thus workability is improved. Further, when the seat cushion 20 in which the snap 24 is integrated is demolded from the molding mold 40, the snap 24 can be detached from the snap retainer 50 by a small force, and thus breakage of the seat cushion 20 and the situation where the snap 24 remains in the lower mold 42 due to the snap 24 not being detached from the snap retainer 50 can be prevented.

[0062] ​Here, if the engagement force of the buckle retainer 50 with the buckle 24 is small, a gap is easily generated between the two. In this case, when the seat cushion 20 is foamed, the foaming material H is caused to intrude into the gap, and the foaming material is attached to the claw portion 30a of the locking piece 30. If the foaming material is attached to the claw portion 30a, the engagement force of the buckle 24 with the mounting tool 26 of the seat cover 18 is reduced. Therefore, in order to ensure the engagement force of the buckle 24 with the mounting tool 26, a repair work of removing the foaming material by post-processing is required.

[0063] On the other hand, if the sizes of the buckle retainer 50 and the buckle 24 are set in such a manner that no gap is generated between the two, in the case where a dimensional error is generated in the buckle 24, a large force is required to set the buckle 24 in the buckle retainer 50, and the workability deteriorates. In particular, in the case where the buckle 24 is made of resin, a dimensional error is easily generated, and the workability easily deteriorates. In addition, after the seat cushion 20 in which the buckle 24 is integrated is molded, when the molded product is demolded from the molding mold 40, it is not easy to generate a defective condition in which the seat cushion 20 is broken due to the fact that the buckle 24 does not separate from the buckle retainer 50, and the buckle 24 remains in the lower mold 42.

[0064] However, according to the manufacturing method of the seat cushion 20 according to the present embodiment, as described above, the timing at which the foaming material H reaches the gap between the claw portion 30a of the locking piece 30 of the buckle 24 is delayed by the eave portion 56 of the buckle retainer 50. Therefore, even if a gap exists between the buckle retainer 50 and the buckle 24 which are set to have a small engagement force, the foaming material can be prevented from being attached to the inner side of the locking piece 30. Thus, the trouble of the repair work of removing the foaming material attached to the inner side of the locking piece 30 can be reduced. In addition, since the foaming material is not attached to the inner side of the locking piece 30, the engagement force of the mounting tool 26 of the seat cover 18 with the buckle 24 can be easily maintained, and the buckle retainer 50 can be repeatedly used while the seat cover 18 is properly held by the seat cushion 20.

[0065] In addition, according to the manufacturing method of the seat cushion 20 according to the present embodiment, the detailed mechanism is not clear, but a gap (a hollow portion which is empty) is not easily generated around the buckle 24. Therefore, the seat cushion 20 can be manufactured with a low defective rate and stably.

[0066] In the present embodiment, the locking portion 54 has a recessed portion 52 which can receive the locking piece 30 and is recessed toward the side, and a separation preventing portion 54a which prevents the locking piece 30 from separating and is bulged toward the side. Figure 9A and Figure 9B is a view of the buckle retainer 50 as viewed from the direction in which the eave portion 56 extends. Figure 9AIn the embodiment, the eaves 56 are arranged to cross the imaginary region X in the left-right direction, and the imaginary region X is the region through which the concave portion 52 passes when the concave portion 52 is imaginarily moved downward. In other words, Figure 9A In the figure, the right end of the eaves portion 56 is located to the right of the right end of the recessed portion 52 , and the left end of the eaves portion 56 is located to the left of the left end of the recessed portion 52 .

[0067] like Figure 9A As shown, the eaves 56 extends across the imaginary area X. Therefore, the eaves 56 can block the foam material H that would otherwise penetrate the concave portion 52 from below and directly through the imaginary area X during foam molding without the eaves 56. The foam material H blocked by the eaves 56 is guided in the direction of the eaves 56's extension, away from the concave portion 52. This delays the time at which the foam material H penetrates the concave portion 52 compared to a situation without the eaves 56. As the foam material H increases in viscosity over time and solidifies, the foam material H that penetrates the concave portion 52 later than the surrounding area can be prevented from entering between the locking portion 54 and the locking piece 30.

[0068] In this embodiment, Figure 9A When viewed from the direction in which the flange portion 56 extends, the two end portions 56b of the flange portion 56 extending in the left-right direction extend upward while being curved along the edge of the concave portion 52. The two end portions 56b can prevent the foam material H located near the imaginary area X from entering the concave portion 52 in a low-viscosity state, thereby more effectively preventing the foam material H from entering between the locking portion 54 and the locking piece 30.

[0069] In addition, it is preferred to Figure 9A In the vertical direction observed from the direction in which the eaves 56 extends, the two end portions 56b of the eaves 56 that cross in the left-right direction extend to a position above the middle position between the upper end 54c of the anti-slip portion 54a and the lower end of the concave portion 52.

[0070] like Figure 11A As shown in the figure, in this embodiment, the eaves 56 extends laterally from the middle position between the lower end and the upper end of the base 55. Here, the lower end of the base 55 is the lower surface of the snap retainer 50 that contacts the lower mold 42. In addition, the upper end of the base 55 is the lower end of the concave portion 52. The middle position does not refer to only a point that is equidistant from the lower end and the upper end of the base 55. The middle position refers to any position in the area extending in the up-down direction between the lower end and the upper end of the base 55. However, it is preferred to extend from Figure 11A When the area between the lower end and the upper end of the base 55 is divided into three equal parts in the vertical direction when viewed in the direction shown, the flange portion 56 extends laterally from the central area.

[0071] Compared to the case where the eave portion 56 extends laterally from the lower end of the base portion 55, it is possible to make the inclination angle of the inclined surface 56a of the eave portion 56 steeper. If the inclination angle is steep, it is easier to more effectively guide the foam material H in the direction away from the recessed portion 52.

[0072] (Alterations)

[0073] Not limited to the foregoing structure, for example, it is also possible to alter as follows.

[0074] (1) In the embodiment, it is a structure in which the eave portion is formed so as to match the opening shape of the recessed portion to the outside in the width direction, and the locking piece that fits into the recessed portion does not overlap the eave portion in the width direction, but it is not limited thereto. For example, it is also possible to form the eave portion so as to cover at least a portion of the outside in the width direction of the recessed portion, in which case the eave portion is disposed so as to overlap the outside in the width direction of the locking piece that fits into the recessed portion. Specifically, as shown in Figure 12 and Figure 13 the eave portion 56 is formed so as to extend upward from the lower edge 52a of the recessed portion 52, and the recessed portion 52 is closed by the eave portion 56 up to the midway position of the side edge 52b of the recessed portion 52. By configuring the eave portion 56 like this, the upper portion of the eave portion 56 overlaps the locking piece 30 that fits into the recessed portion 52, and it is possible to make it difficult for the foam material H to intrude from between the locking piece 30 and the lower edge 52a of the recessed portion 52, or between the locking piece 30 and the lower portion of the side edge 52b of the recessed portion 52. Furthermore, the eave portion 56 can be formed so as to cover the recessed portion 52 up to the upper portion of the side edge 52b of the recessed portion 52, as long as it is a shape that does not interfere with the fitting of the locking piece 30 into the recessed portion 52.

[0075] (2) In the embodiment, the clasp holding unit and the male portion of the lower mold are configured separately, but it is not limited thereto, and the clasp holding unit can be formed integrally with the male portion.

[0076] (3) The material of the clasp and the clasp holding unit is not limited to the embodiment. For example, the clasp can be made of metal.

[0077] This application is based on Japanese Patent Application (JP-A) No. 2019-008427, filed on January 22, 2019, the contents of which are incorporated herein by reference.

[0078] Industrial Applicability

[0079] According to the clasp holding unit and the molding mold related to the present application, it is possible to easily attach and detach the clasp, and it is possible to prevent the foam from adhering to unnecessary portions.

[0080] According to the manufacturing method of a seat cushion related to the present application, it is possible to easily attach and detach the clasp, and it is possible to prevent the foam from adhering to unnecessary portions.

[0081] Reference Signs List

[0082] 10 seat

[0083] 12 seat portion

[0084] 14 backrest portion

[0085] 16 headrest

[0086] 18 seat cover

[0087] 20 seat cushion

[0088] 22 groove portion

[0089] 24 catch

[0090] 26 installation tool

[0091] 28 base portion

[0092] 28a through-hole

[0093] 30 locking piece

[0094] 30a claw portion

[0095] 40 molding mold

[0096] 42 lower mold

[0097] 42a lower mold surface

[0098] 44 upper mold

[0099] 46 cavity

[0100] 48 male mold portion (groove forming portion)

[0101] 48a provided recess

[0102] 50 catch holder (catch holding unit)

[0103] 51 side wall surface

[0104] 52 concave portion

[0105] 52a lower edge

[0106] 52b side edge

[0107] 54 locking portion

[0108] 54a anti-disengagement portion

[0109] 55 base portion

[0110] 56...eave portion

[0111] 56a...inclined surface

[0112] 56b...end portion

[0113] X...imaginary region

[0114] H...foam raw material

Claims

1. A buckle holder that can be detachably mounted on a molding die for foaming a seat cushion. The buckle retainer has: A locking portion for locking the buckle; extending from the bottom surface of the buckle holder to the base of the locking portion; and The eaves portion extends laterally from the base portion toward the locking portion from the bottom surface. With the bottom surface as a reference, the length to the end of the locking portion is greater than the length to the end of the eaves portion.

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