Occupant seat cushion member manufacturing method, occupant seat cushion member, filler manufacturing method, and filler

Abstract

The passenger seat cushion member manufacturing method is a method of manufacturing a passenger seat cushion member provided with a seat main body and a filler filled in a hole portion formed in the seat main body, in which: the seat main body includes a seat main body-side connection portion having a mechanical connection means connected to the filler; the filler includes a main body portion and a filler-side connection portion, the main body portion includes a porous structure made of a flexible resin or rubber, the filler-side connection portion has a mechanical connection means adjacent to the main body portion and connected to the seat main body-side connection portion, and at least a portion of the filler-side connection portion is made of a porous structure; the density of a portion including the porous structure in the filler-side connection portion is higher than the density of the main body portion, the method comprising: a step of molding the porous structure using a 3D printer; and a step of filling the seat body with a filler by connecting a filler-side connecting part including the molded porous structure to the seat body-side connecting part.

Description

[0001] This application is a divisional application of the invention patent application with application number 202080027989.9 (the corresponding international application number is PCT / JP2020 / 006074), application date February 17, 2020, and invention name “Passenger seat cushion component manufacturing method, passenger seat cushion component, filler body manufacturing method and filler body”. Technical Field

[0002] The present disclosure relates to a method for manufacturing a passenger seat cushion member, a passenger seat cushion member, a method for manufacturing a filler, and a filler. Background Art

[0003] Conventionally, porous structures (e.g., polyurethane foam) having cushioning properties have been manufactured by a process such as chemical reaction foaming in mold molding (e.g., Patent Document 1). In addition, for example, a filler including such a porous structure as described above may be filled in a seat body to locally adjust the properties of the passenger seat cushioning member.

[0004] This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2019-76047 filed in Japan on April 12, 2019; the entire contents of which are incorporated herein by reference.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2016-44292 Summary of the invention

[0008] Problem that the invention aims to solve

[0009] However, when the porous structure is manufactured by the process of chemical reaction foaming as described above, the porous structure has a substantially uniform cushioning property as a whole, and since softness accompanies the cushioning property, it is not easy to firmly mount the filler including the porous structure to the seat body. Moreover, it is desired to easily mount the filler to the seat body.

[0010] The present disclosure aims to provide: a method for manufacturing a passenger seat cushioning member, the method being capable of obtaining a passenger seat cushioning member including a filling body, the filling body including a porous structure and being capable of being easily and firmly mounted to a seat body; a passenger seat cushioning member, the filling body including a porous structure and being capable of being easily and firmly mounted to a seat body; a method for manufacturing a filling body, the method being capable of obtaining a filling body including a porous structure and being easily and firmly mounted to a seat body; a filling body, the filling body including a porous structure and being easily and firmly mounted to a seat body.

[0011] Solutions for solving problems

[0012] The manufacturing method of the passenger seat buffer member disclosed in the present invention is:

[0013] A method for manufacturing a passenger seat cushion component, the method being used to manufacture the passenger seat cushion component, the passenger seat cushion component comprising a seat body and a filling body for filling a hole formed in the seat body.

[0014] The seat body includes a seat body side connection portion, and the seat body side connection portion includes a mechanical connection means connected to the filling body,

[0015] The filling body includes a main body, the main body includes a porous structure and a filling body side connecting part, the porous structure is made of flexible resin or rubber, the filling body side connecting part is arranged adjacent to the main body and includes a mechanical connecting means connected to the seat body side connecting part, at least a part of the filling body side connecting part includes the porous structure,

[0016] The density of the portion including the porous structure in the filling body side connecting portion is higher than the density of the main body portion, and the manufacturing method includes:

[0017] The step of forming the porous structure by using a 3D printer; and

[0018] A step of joining the filling body side joining portion including the formed porous structure to the seat body side joining portion to fill the seat body with the filling body.

[0019] The passenger seat cushioning member of the present disclosure is:

[0020] A passenger seat cushion member includes a seat body and a filling body for filling a hole formed in the seat body, wherein

[0021] The seat body includes a seat body side connection portion, and the seat body side connection portion includes a mechanical connection means connected to the filling body,

[0022] The filling body comprises a main body and a filling body side connecting part, the main body comprising a porous structure made of flexible resin or rubber, the filling body side connecting part is arranged adjacent to the main body and comprises a mechanical connecting means connected to the seat main body side connecting part, at least a part of the filling body side connecting part comprises the porous structure,

[0023] The density of a portion of the filling body side connecting portion including the porous structure is higher than the density of the main body portion, the filling body side connecting portion is connected to the seat main body side connecting portion, and

[0024] The porous structure is formed by using a 3D printer.

[0025] The filling body manufacturing method disclosed in the present invention is:

[0026] A method for manufacturing a filling body that fills a hole portion formed in a seat body of a passenger seat cushioning member including a seat body and the filling body,

[0027] The filling body includes a main body portion and a filling body side connecting portion, the main body portion includes a porous structure made of flexible resin or rubber, the filling body side connecting portion is arranged adjacent to the main body portion and includes a mechanical connecting means connected to the seat body, at least a part of the filling body side connecting portion includes the porous structure,

[0028] The density of the portion including the porous structure in the filling body side connecting portion is higher than the density of the main body portion.

[0029] The manufacturing method comprises:

[0030] The step of forming the porous structure by using a 3D printer.

[0031] The filler body of the present disclosure is:

[0032] A filling body is provided for filling a hole formed at a seat body in a passenger seat cushion member, wherein the passenger seat cushion member comprises the seat body and the filling body.

[0033] The filling body includes a main body portion and a filling body side connecting portion, the main body portion includes a porous structure made of flexible resin or rubber, the filling body side connecting portion is arranged adjacent to the main body portion and includes a mechanical connecting means connected to the seat body, at least a part of the filling body side connecting portion includes the porous structure,

[0034] The density of the portion including the porous structure in the filling body side connecting portion is higher than the density of the main body portion, and

[0035] The porous structure is formed by using a 3D printer.

[0036] Effects of the Invention

[0037] According to the present disclosure, there can be provided: a method for manufacturing a passenger seat cushioning component, which is capable of obtaining a passenger seat cushioning component including a filling body, the filling body including a porous structure and being easily and firmly mounted to a seat body; a passenger seat cushioning component, which includes a filling body, the filling body including a porous structure and being easily and firmly mounted to a seat body; a method for manufacturing a filling body, which is capable of obtaining a filling body including a porous structure and being easily and firmly mounted to a seat body; a filling body, which includes a porous structure and being easily and firmly mounted to a seat body. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 is a perspective view showing a portion of an example of a porous structure that may be included in a passenger seat cushion member filler according to an embodiment of the present disclosure.

[0039] Figure 2 is shown along Figure 1 Observe in the direction of arrow A Figure 1 A-arrow view of the porous structure in .

[0040] Figure 3 is shown along Figure 1 Observe in the direction of arrow B Figure 1 B-arrow view of the porous structure in .

[0041] Figure 4 It is shown Figure 1 A three-dimensional diagram of the bubble partitioning portion of the porous structure in FIG.

[0042] Figure 5 is corresponding to Figure 4 , and is an explanatory diagram of a deformation example of the bubble zoning portion.

[0043] Figure 6 is corresponding to Figure 1 , and is a perspective view showing a portion of a first modification example of the porous structure.

[0044] Figure 7 is shown along Figure 6 Observe in the direction of arrow D Figure 6 Arrow view of portion C of the porous structure in D.

[0045] Figure 8 is shown along Figure 6 Observe in the direction of arrow E Figure 6 Arrow E view of portion C of the porous structure.

[0046] Fig. 9 is corresponding to Figure 1 , and is a perspective view showing a portion of a second modification example of the porous structure.

[0047] Fig.10 is shown along Fig. 9 Observe in the direction of arrow G Fig. 9 G arrow view of the F portion of the porous structure.

[0048] Fig.11 is shown along Fig. 9 Observe in the direction of arrow H Fig. 9 H arrow view of the F portion of the porous structure.

[0049] Fig.12 is a perspective view showing a car seat pad as a passenger seat cushion member according to an embodiment of the present disclosure.

[0050] Fig.13 It is shown Fig.12 A perspective view of details of the main pad and side pads in a car seat cushion.

[0051] Fig.14 It is shown Fig.13 A three-dimensional view of the main cushion in the seat body.

[0052] Fig.15 It is shown Fig.14 A top view of the seat body in FIG.

[0053] Fig.16 yes Fig.14 II cross-sectional view of the seat body.

[0054] Fig.17 yes Fig.14 JJ cross-sectional view of the seat body.

[0055] Fig.18 It is shown Fig.13 A three-dimensional view of the filling body in the main pad.

[0056] Fig.19 yes Fig.18 KK cross-sectional view of the filling body in .

[0057] Fig. 20 yes Fig.18 LL cross-section of the filling body in.

[0058] Fig.21 It is shown Fig.18 A stereoscopic view of a deformation example of the filling body.

[0059] Fig. 22 yes Fig.21 MM cross-section of the filling body in.

[0060] Fig.23 yes Fig.21 NN cross-section of the filling body in.

[0061] Fig.24 is corresponding to Fig.13 , and is a perspective view showing details of a first modification example of the main pad and the side pad.

[0062] Fig.25 yes Fig.24 An enlarged top view of section P in FIG.

[0063] Fig.26is corresponding to Fig.13 , and is a perspective view showing details of a second modification of the main pad and the side pad.

[0064] Fig. 27 yes Fig.26 Magnified top view of section Q in FIG.

[0065] Fig.28 According to the embodiments of the present disclosure Figure 1 An explanatory diagram of a method for producing a porous structure of an example in FIG.

[0066] Fig.29 It is shown Figures 1 to 4 A plan view of a portion of a modified example of a skeleton portion.

[0067] Fig.30 (a) shows Fig.29 A three-dimensional image of the skeleton without external force applied. Fig.30 (b) shows Fig.30 (a) is a stereoscopic image of the bone part in a state where an external force is applied. DETAILED DESCRIPTION

[0068] The passenger seat cushion member manufactured by using the passenger seat cushion member manufacturing method according to the present disclosure and the passenger seat cushion member according to the present disclosure may be included in any type of passenger seat cushion member, and is preferably included in a vehicle seat cushion member, for example, and is more preferably included in an automobile seat cushion.

[0069] Embodiments of a passenger seat cushion member manufacturing method, a passenger seat cushion member, a filler body manufacturing method, and a filler body according to the present disclosure will be exemplarily described below with reference to the accompanying drawings.

[0070] Any common components in the drawings will be indicated by the same reference numeral.

[0071] also, Figures 1 to 11 The orientation of the XYZ orthogonal coordinate system fixed to the porous structure is shown to help understand the orientation of the porous structure.

[0072] First, refer to Figures 1 to 4 A porous structure included in a car seat pad, which is a passenger seat cushion member according to an embodiment of the present disclosure, is described.

[0073] exist Figures 1 to 3 In the figure, the portion of the porous structure 1 in the present embodiment having a substantially rectangular parallelepiped shape is observed at different angles. Figure 1 1 is a perspective view showing relevant parts of the porous structural body 1 . Figure 2 The diagram shows the direction of arrow A (Y direction). Figure 1A arrow view of this portion of the porous structure 1 in FIG. Figure 3 Observed along the direction of arrow B (-Z direction) Figure 1 B arrow view of this part of the porous structure 1.

[0074] The porous structure 1 is formed by a 3D printer. The entire porous structure 1 is integrated. Since the porous structure 1 is manufactured by using a 3D printer, the porous structure can be easily manufactured compared to the case where the porous structure undergoes a foaming process by a chemical reaction in a conventional case, and a desired configuration can be obtained. In addition, due to the continuous advancement of 3D printer technology, it can be expected that manufacturing by a 3D printer can be achieved in a shorter time and at a lower cost in the future.

[0075] The porous structure 1 is made of a flexible resin or rubber. More specifically, the porous structure 1 includes a skeleton portion 2 as the skeleton of the porous structure 1. The skeleton portion 2 divides a large number of bubble pores C. The skeleton portion 2 is substantially present in the entire porous structure 1 and is made of a flexible resin or rubber. In this example, the portion of the porous structure 1 other than the skeleton portion 2 is a void space, in other words, the porous structure 1 includes only the skeleton portion 2.

[0076] Here, the "flexible resin" is a resin that can be deformed when an external force is applied, and is preferably, for example, an elastomeric resin, more preferably polyurethane, and further preferably soft polyurethane. The rubber is, for example, natural rubber or synthetic rubber. The porous structure 1 made of a flexible resin or rubber can be compressed and restored to deform according to the application and release of an external force, and can have a cushioning property.

[0077] Note that, for ease of manufacture by a 3D printer, the porous structural body 1 is more preferably made of a flexible resin rather than rubber.

[0078] like Figures 1 to 3 As shown, the skeleton part 2 of the porous structure 1 includes a plurality of bone parts 2B and a plurality of joint parts 2J, and the entire skeleton part 2 is integrated. Each bone part 2B is columnar in this example and extends in a straight line in this example. Each joint part 2J joins the end parts 2Be of a plurality of (for example, 4) bone parts 2B extending in different directions from each other at a position where the end parts 2Be are adjacent to each other.

[0079] Figures 1 to 3The skeleton line O of the skeleton part 2 in a part of the porous structure 1 is shown by a dotted line. The skeleton line O of the skeleton part 2 includes the skeleton line O of each bone part 2B and the skeleton line O of each joint part 2J. The skeleton line O of the bone part 2B is the central axis of the bone part 2B. The skeleton line O of the joint part 2J is an extended line portion obtained when the central axis of the bone part 2B joined by the joint part 2J smoothly extends into the joint part 2J and is connected to each other.

[0080] The extending direction of each bone portion 2B is the extending direction of the skeleton line O of the bone portion 2B (the portion of the skeleton line O corresponding to the bone portion 2B, the same below).

[0081] The porous structure 1 including the skeleton part 2 as a whole can be compressed and deformed according to the application and release of external force while ensuring air permeability, and thus has excellent characteristics as a passenger seat cushion member. In addition, the porous structure 1 has a simple structure and can therefore be easily formed by a 3D printer.

[0082] Note that part or all of the bone parts 2B included in the skeleton part 2 may extend in a curved shape. In this case, since part or all of the bone parts 2B are curved, a sharp change in shape of the bone parts 2B and thus a sharp change in shape of the porous structure 1 can be prevented when a force is input, and local buckling can be reduced.

[0083] In this example, each bone portion 2B included in the skeleton portion 2 has substantially the same shape and length. However, the present disclosure is not limited to this example, and the shapes and / or lengths of the bone portions 2B included in the skeleton portion 2 may be different, for example, the shape and / or length of a portion of the bone portion 2B may be different from the shape and / or length of other bone portions 2B. In this case, different mechanical properties can be intentionally obtained by making the shape and / or length of the bone portion 2B at a specific portion of the skeleton portion 2 different from that at other portions.

[0084] In this example, the width W0 of each bone portion 2B ( Figure 1 ) and the cross-sectional area are constant over the entire length of the bone portion 2B (ie, uniform along the extension direction of the bone portion 2B).

[0085] Here, the cross-sectional area of ​​the bone portion 2B is the cross-sectional area of ​​the cross section of the bone portion 2B perpendicular to the skeleton line O. In addition, the width W0 ( Figure 1 ) is the maximum width in a cross section measured along a cross section of the bone portion 2B perpendicular to the skeleton line O.

[0086] However, in each example described in the present specification, in a part or all of the bone parts 2B of each bone part 2B included in the skeleton part 2, the width W0 and / or the cross-sectional area of ​​each bone part 2B may be non-uniform along the extension direction of the bone part 2B. For example, in a portion of the end 2Be located on each side in the extension direction of the bone part 2B of each of the part or all of the bone parts 2B of each bone part 2B included in the skeleton part 2, the width W0 of the bone part 2B may gradually increase or decrease as the position goes toward each end in the extension direction of the bone part 2B. In addition, in a portion of the end 2Be located on each side in the extension direction of the bone part 2B of each of the part or all of the bone parts 2B of each bone part 2B included in the skeleton part 2, the cross-sectional area of ​​the bone part 2B may gradually increase or decrease as it goes toward each end in the extension direction of the bone part 2B.

[0087] In each example described in this specification, in order to simplify the structure of the skeleton part 2 and thus to facilitate the manufacture of the porous structure 1 by a 3D printer, the width W0 ( Figure 1 ) is preferably 0.05 mm or more, more preferably 0.10 mm or more. When the width W0 is 0.05 mm or more, it can be formed at the resolution of a high-performance 3D printer, and when the width is 0.10 mm or more, it can be formed not only at the resolution of a high-performance 3D printer but also at the resolution of a general-purpose 3D printer.

[0088] On the other hand, in order to improve the accuracy of the outer edge (outer contour) shape of the skeleton portion 2, reduce the gaps (intervals) between the cells C, and have excellent properties as a buffer member, the width W0 of the bone portion 2B is preferably 2.0 mm or less.

[0089] Note that it is preferred that each bone portion 2B included in the skeleton portion 2 satisfies the above configuration, but only a portion of the bone portions 2B included in the skeleton portion 2 may satisfy the above configuration, and in this case, the same effect can also be obtained to varying degrees.

[0090] In the present example, each bone portion 2B included in the skeleton portion 2 is columnar, and has a circular (perfect circle) cross section.

[0091] As a result, the skeleton part 2 has a simple structure and can therefore be easily formed by a 3D printer. In addition, the mechanical properties of a general polyurethane foam manufactured by a chemical reaction foaming process can be easily reproduced. Since each bone part 2B is columnar in this way, the durability of the skeleton part 2 can be improved compared to the case where the bone part 2B is replaced by a film part.

[0092] Note that the cross-sectional shape of each bone portion 2B is a shape at a cross section perpendicular to the central axis (skeleton line O) of the bone portion 2B.

[0093] Note that the present disclosure is not limited to this example, and only a part of the bone parts 2B included in the skeleton part 2 may satisfy the above-described configuration, in which case the same effect can be obtained to varying degrees.

[0094] For example, in each example described in this specification, in all or part of the bone parts 2B of each bone part 2B included in the skeleton part 2, the cross-sectional shape of each bone part 2B can be a polygon (equilateral triangle, triangle other than equilateral triangle, rectangle, etc.) or can be a circle other than a perfect circle (ellipse, etc.), and in this case, the same effect as that of this example can be obtained. In addition, the cross-sectional shape of the bone part 2B can be uniform along the extension direction, or non-uniform along the extension direction. In addition, the cross-sectional shapes of the individual bone parts 2B can be different from each other.

[0095] In this example, the skeleton portion 2 includes a plurality of (the number of the pores C) bubble partitioning portions 21 each partitioning the pores C therein.

[0096] Figure 4 Only one bubble partitioning portion 21 is shown. In the skeleton portion 2 of this example, a plurality of bubble partitioning portions 21 have a structure in which they are arranged in a row in each of the X direction, the Y direction, and the Z direction.

[0097] like Figures 1 to 3 As shown, each bubble partitioning portion 21 includes a plurality of (14 in this example) annular portions 211. Each annular portion 211 is annular, and an annular inner peripheral side edge portion 2111 of the annular portion 211 partitions a flat imaginary surface V1. The plurality of annular portions 211 included in the bubble partitioning portion 21 are connected to each other in such a manner that the imaginary surfaces V1 partitioned by the corresponding inner peripheral side edge portions 2111 of the annular portions 211 do not intersect each other.

[0098] Each bubble hole C is demarcated by a plurality of annular portions 211 included in the bubble demarcation portion 21 and a plurality of imaginary surfaces V1 demarcated by the plurality of annular portions 211. Schematically, each annular portion 211 is a portion of an edge that demarcates the three-dimensional shape of the bubble hole C, and each imaginary surface V1 is a portion of a constituent surface that demarcates the three-dimensional shape of the bubble hole C.

[0099] Each annular portion 211 includes a plurality of bone portions 2B and a plurality of coupling portions 2J coupling end portions 2Be of the plurality of bone portions 2B.

[0100] The joint of each pair of annular portions 211 connected to each other includes a bone portion 2B and a pair of joint portions 2J, which are located on both sides of the bone portion shared by the pair of annular portions 211. That is, each bone portion 2B and each joint portion 2J are shared by a plurality of adjacent annular portions 211.

[0101] For each imaginary surface V1, the surface on one side of the imaginary surface V1 (the front surface of the imaginary surface V1) defines a portion of the pores C, and the surface on the other side of the imaginary surface V1 (the rear surface of the imaginary surface V1) defines a portion of another pore C. In other words, the front surface and the rear surface of each imaginary surface V1 define portions of different pores C. In other words, each imaginary surface V1 is shared by a pair of pores C adjacent to the imaginary surface V1 (i.e., a pair of pores C sandwiching the imaginary surface V1).

[0102] Each annular portion 211 is shared by a pair of bubble compartments 21 adjacent to the annular portion 211 (ie, a pair of bubble compartments 21 sandwiching the annular portion 211). In other words, each annular portion 211 constitutes a portion of a pair of bubble compartments 21 adjacent to each other.

[0103] In this example, each virtual surface V1 is not covered by a film 3 ( Figure 5 ) is not covered, but is open, in other words, has an opening. Therefore, the bubble pores C are connected to each other through the imaginary surface V1 to allow ventilation between the bubble pores C. Therefore, the air permeability of the skeleton part 2 can be improved, and the compression and recovery deformation of the skeleton part 2 according to the application and release of external force can be easily performed.

[0104] like Figure 4 As shown, in this example, the skeleton line O of each bubble partitioning portion 21 has a polyhedral shape, and therefore, each bubble hole C has a substantially polyhedral shape. More specifically, Figures 1 to 3 In the example, the skeleton line O of each bubble partitioning portion 21 has a Kelvin tetradecahedron (truncated octahedron) shape, and therefore, each bubble hole C has a substantially Kelvin tetradecahedron (truncated octahedron) shape. The Kelvin tetradecahedron (truncated octahedron) is a polyhedron including six square constituent faces and eight regular hexagonal constituent faces. Schematically, the bubble holes C included in the skeleton portion 2 are regularly arranged to spatially fill the internal space surrounded by the outer edge (outer contour) of the skeleton portion 2 (that is, the individual bubble holes C are laid out in a manner such that there is no wasted gap, in other words, the gaps (intervals) between the bubble holes C are reduced).

[0105] As in the present example, when the shape of the skeleton line O of each of a part or all (in the present example, all) of the bubble partitioning portions 21 of the skeleton portion 2 (i.e., the shape of each of a part or all (in the present example, all) of the bubble pores C of the skeleton portion 2) is a polyhedron, the gaps (intervals) between the bubble pores C included in the skeleton portion 2 can be further reduced, and a greater number of bubble pores C can be formed inside the skeleton portion 2. In addition, with this configuration, the behavior of the skeleton portion 2 (i.e., the porous structural body 1) in terms of compression and recovery deformation according to the application and release of external forces is more advantageous as a passenger seat cushion member, especially as a car seat cushion.

[0106] The polyhedral shape of the skeleton line O of the bubble partitioning portion 21 (i.e., the polyhedral shape of the bubble pores C) is not limited to the present example and may be arbitrary. For example, in order to reduce the gap (interval) between the bubble pores C, a configuration in which the shape of the skeleton line O of the bubble partitioning portion 21 (i.e., the shape of the bubble pores C) is a substantially tetrahedral, substantially octahedral, or substantially dodecahedral shape is preferred. Alternatively, the shape of the skeleton line O of each of a part or all of the bubble partitioning portions 21 of the skeleton portion 2 (i.e., the shape of a part or all of the bubble pores C of the skeleton portion 2) may be a three-dimensional shape other than a substantially polyhedral shape (e.g., a sphere, an ellipsoid, a cylinder, etc.). In addition, as the bubble partitioning portion 21, the skeleton portion 2 may include only one type of bubble partitioning portion 21 having the same shape of the skeleton line O, or may include a plurality of types of bubble partitioning portions 21 having different shapes of the skeleton line O. Similarly, as the bubble pores C, the skeleton portion 2 may include only one type of bubble pores C having the same shape, or may include a plurality of types of bubble pores C having different shapes. Note that, as in the present example, when the shape of the skeleton line O of each bubble partition portion 21 (i.e., the shape of each bubble hole C) is approximately a Kelvin tetradecahedron (truncated octahedron), it is easiest to reproduce the cushioning component characteristics equivalent to the cushioning component characteristics of a general polyurethane foam manufactured by a chemical reaction foaming process, compared to other shapes.

[0107] like Figures 1 to 4 As shown, in this example, each of the plurality of (14 in this example) annular portions 211 included in the bubble partitioning portion 21 includes one or more (6 in this example) small annular portions 211S and one or more (8 in this example) large annular portions 211L. The annular inner peripheral side edge 2111 of each small annular portion 211S defines a small imaginary surface V1S. The annular inner peripheral side edge 2111 of each large annular portion 211L defines a large imaginary surface V1L having an area larger than that of the small imaginary surface V1S.

[0108] As from Figure 4It can be seen that in this example, the skeleton line O of each large annular portion 211L is a regular hexagon, so the corresponding large imaginary surface V1L is also a roughly regular hexagon. In addition, in this example, the skeleton line O of each small annular portion 211S is a square, so the corresponding small imaginary surface V1S is also a roughly square. Therefore, in this example, the small imaginary surface V1S and the large imaginary surface V1L are different from each other not only in area but also in shape.

[0109] Each large annular portion 211L includes a plurality of (six in this example) bone portions 2B and a plurality of (six in this example) joint portions 2J for joining the ends 2Be of the plurality of bone portions 2B. Each small annular portion 211S includes a plurality of (four in this example) bone portions 2B and a plurality of (four in this example) joint portions 2J for joining the ends 2Be of the plurality of bone portions 2B.

[0110] Since the plurality of annular portions 211 included in the bubble partitioning portion 21 include the small annular portion 211S and the large annular portion 211L of different sizes, the gaps (intervals) between the bubble pores C included in the skeleton portion 2 can be further reduced. In addition, as in the present example, when the shapes of the small annular portion 211S and the large annular portion 211L are different from each other, the gaps (intervals) between the bubble pores C included in the skeleton portion 2 can be further reduced.

[0111] However, the plurality of annular portions 211 included in the bubble partitioning portion 21 may have the same size and / or shape. When the annular portions 211 included in the bubble partitioning portion 21 have the same size and shape, the same mechanical properties may be obtained in the X direction, the Y direction, and the Z direction, respectively.

[0112] As in the present example, when the skeleton line O of a part or all (in the present example, all) of the annular portions 211 included in the bubble partitioning portion 21 (i.e., a part or all (in the present example, all) of the imaginary surfaces V1 included in the bubble partitioning portion 21) has a substantially polygonal shape, the intervals between the bubble holes C included in the skeleton portion 2 can be further reduced. In addition, the compression and recovery deformation behavior of the skeleton portion 2 according to the application and release of external forces is more conducive to being used as a passenger seat cushion member, especially as a car seat cushion. Since the shape of each annular portion 211 (i.e., the shape of each imaginary surface V1) is simple, it is possible to improve the manufacturability and the ease of characteristic adjustment. Note that when at least one of the annular portions 211 included in the skeleton portion 2 (i.e., at least one of the imaginary surfaces V1 included in the skeleton portion 2) satisfies the above-mentioned configuration, the same effect can be obtained to varying degrees.

[0113] Note that the skeleton line O of at least one of the annular portions 211 included in the skeleton portion 2 (i.e., at least one of the imaginary surfaces V1 included in the skeleton portion 2) may have any roughly polygonal shape other than the roughly regular hexagonal shape and the roughly square shape as in the present example, or have a planar shape other than the roughly polygonal shape (e.g., circular (such as a perfect circle or an ellipse, etc.)). When the shape of the skeleton line O of each annular portion 211 (i.e., the shape of each imaginary surface V1) is circular (such as a perfect circle or an ellipse, etc.), the shape of each annular portion 211 (i.e., the shape of the imaginary surface V1) is simple. Therefore, the manufacturability and the ease of characteristic adjustment can be improved, and more uniform mechanical characteristics can be obtained. For example, when the shape of the skeleton line O of each annular portion 211 (i.e., the shape of each imaginary surface V1) is an ellipse that is long in a direction approximately perpendicular to the direction in which weight is applied (a horizontally long ellipse), the annular portion 211, that is, the skeleton portion 2 (i.e., the porous structure 1) is easily deformed (softened) in response to the input of force, compared to the case where the shape is an ellipse that is long in a direction approximately parallel to the direction in which weight is applied (a vertically long ellipse).

[0114] In this example, it is preferred that the skeleton part 2 includes at least one bubble pore C having a diameter of 5 mm or more. Therefore, the porous structure 1 can be easily manufactured by using a 3D printer. When the diameter of each bubble pore C of the skeleton part 2 is less than 5 mm, the structure of the skeleton part 2 is so complicated that it may be difficult to generate three-dimensional shape data (such as CAD data, etc.) representing the three-dimensional shape of the porous structure 1 or 3D forming data generated based on the three-dimensional shape data on a computer.

[0115] Note that, since the conventional porous structure included in the passenger seat cushion member is manufactured through a chemical reaction foaming process, it is impossible to form the cell C having a diameter of 5 mm or more.

[0116] Furthermore, since the skeleton portion 2 includes the pores C having a diameter of 5 mm or more, the air permeability and the ease of deformation of the skeleton portion 2 can be easily improved.

[0117] Therefore, the diameters of all the cells C included in the skeleton portion 2 are preferably 5 mm or more.

[0118] As the diameter of each bubble pore C increases, the porous structure 1 (i.e., the passenger seat cushioning member) can be more easily manufactured by using a 3D printer, and the air permeability and the ease of deformation can be more easily improved. Therefore, the diameter of at least one bubble pore C (preferably, all bubble pores) in the skeleton part 2 is preferably 8 mm or more, and more preferably 10 mm or more.

[0119] On the other hand, when each bubble pore C in the skeleton portion 2 is too large, it is difficult to neatly (smoothly) form the outer edge (outer contour) shape of the skeleton portion 2 (i.e., the porous structural body 1), which may result in reduced shape accuracy and poor appearance of the passenger seat cushioning member. In addition, the characteristics of the passenger seat cushioning member may not be sufficiently good. Therefore, in order to improve the appearance and the characteristics of the passenger seat cushioning member, the diameter of each bubble pore C in the skeleton portion 2 is preferably 30 mm or less, more preferably 25 mm or less, and further more preferably 20 mm or less.

[0120] Note that when the pores C have a shape other than a strictly spherical shape as in the present example, the diameter of the pores C is the diameter of a circumscribed sphere of the pores C.

[0121] When each bubble pore C in the skeleton part 2 is too small, the structure of the skeleton part 2 becomes too complicated. As a result, it may be difficult to generate three-dimensional shape data (such as CAD data, etc.) representing the three-dimensional shape of the porous structure 1 or 3D forming data generated based on the three-dimensional shape data on a computer, and even if the data can be generated, it may be difficult to form according to the 3D forming data by a 3D printer. Therefore, it is difficult to manufacture the porous structure 1 by using a 3D printer. In order to facilitate the manufacture of the porous structure 1 (i.e., the passenger seat cushioning member) by using a 3D printer, the diameter of the bubble pore C of each bubble pore C included in the skeleton part 2 and having the smallest diameter is preferably 0.05 mm or more, and more preferably 0.10 mm or more. When the diameter of the bubble pore C with the smallest diameter is 0.05 mm or more, it can be formed at the resolution of a 3D printer with high performance, and when the diameter is 0.10 mm or more, it can be formed not only at the resolution of a 3D printer with high performance, but also at the resolution of a general 3D printer.

[0122] Figure 5 is an explanatory diagram of a modified example of the bubble partitioning portion 21 of the porous structure 1, and corresponds to Figure 4 In each example described in this specification, as in Figure 5 In the illustrated variant, the porous structure 1 may include one or more membranes 3 in addition to the skeleton 2 .

[0123] Each film 3 extends on the imaginary plane V1 defined by the annular inner peripheral side edge portion 2111 of the annular portion 211, and thus covers the imaginary plane V1 defined by the annular portion 211. Figure 5 In the porous structure 1 in the example of , at least one of the imaginary surfaces V1 included in the skeleton part 2 is covered with a membrane 3. The membrane 3 is made of the same material as that in the skeleton part 2 and is integrated with the skeleton part 2. Figure 5In the example of , the film 3 is formed flat. However, the film 3 may be formed unevenly (for example, in a curved shape (curved surface shape)).

[0124] Preferably, the thickness of the membrane 3 is smaller than the width W0 of the bone portion 2B ( Figure 1 ).

[0125] The membrane 3 prevents the connection between the two bubble holes C sandwiching the imaginary surface V1 through the imaginary surface V1, and it is impossible to ventilate through the imaginary surface V1. Therefore, the air permeability of the porous structure 1 as a whole is reduced. The air permeability of the entire porous structure 1 can be adjusted by adjusting the number of imaginary surfaces V1 included in the porous structure 1 and covered with the membrane 3, and various air permeability levels can be achieved as needed. For example, when the porous structure 1 is used for a passenger seat cushioning member, the performance, anti-stuffiness and riding comfort of the vehicle air conditioner can be improved by adjusting the air permeability of the porous structure 1. When the porous structure 1 is used for a passenger seat cushioning member, in order to improve the performance, anti-stuffiness and riding comfort of the vehicle air conditioner, it is not preferred that all the imaginary surfaces V1 included in the porous structure 1 are covered with the membrane 3. In other words, it is preferred that at least one of the imaginary surfaces V1 included in the porous structure 1 is not covered with the membrane 3 and is open.

[0126] Note that since the conventional porous structure has been manufactured by the process of chemical reaction foaming as described above, it is difficult to form a desired number of membranes for communicating holes for communicating bubbles with each other at a desired position. When the porous structure 1 (i.e., the passenger seat cushioning member) is manufactured by a 3D printer as in this example, information of the membrane 3 is included in advance in the 3D forming data to be read by the 3D printer, so the desired number of membranes 3 can be reliably formed at the desired position.

[0127] For the same reason, at least one of the small imaginary surfaces V1S included in the skeleton portion 2 may be covered with the film 3. Additionally or alternatively, at least one of the large imaginary surfaces V1L included in the skeleton portion 2 may be covered with the film 3.

[0128] In each example described in this specification, when the porous structure 1 is used for a passenger seat cushion member, in order to improve the performance of air conditioning, anti-stuffiness and riding comfort, the air permeability of the porous structure 1 is preferably 100 cc / cm 2 / sec to 700cc / cm 2 / sec, more preferably 150cc / cm 2 / sec to 650cc / cm 2 / sec, and more preferably 200cc / cm 2 / sec to 600cc / cm 2 / sec. Here, the air permeability (cc / cm 2 / sec) is measured in accordance with JIS K 6400-7. When the porous structural body 1 is used for a passenger seat cushion member, the resonance magnification of the porous structural body 1 is preferably 3 times or more and 8 times or less, more preferably 3 times or more and 5 times or less.

[0129] Figures 6 to 8 It is an explanatory diagram of a first modified example of the porous structure 1 . Figure 6 is a perspective view showing a portion of a first modification of the porous structure 1, and corresponds to Figure 1 . Figure 7 is shown along Figure 6 Observed in the direction of arrow D (Y direction) Figure 6 Arrow D view of the porous structure of portion C surrounded by the dotted line. Figure 8 The diagram shows the observation along the direction of arrow E (-Z direction). Figure 6 The E arrow view of the C portion of the porous structure 1.

[0130] In this example, the porous structure 1 includes a skin portion 6 in addition to the skeleton portion 2. In this case, the porous structure 1 may or may not include the above-mentioned membrane 3 ( Fig.10 ) The above is the description of the structures of the skeleton portion 2 and the membrane 3.

[0131] The skin portion 6 is integrated with the frame portion 2 to cover a part or all of the outer surface of the frame portion 2 (the imaginary surface in the outer edge (outer contour) of the frame portion 2), and the skin portion 6 is made of the same material as that in the frame portion 2. The skin portion 6 is formed on a part or all of the outer surface of the passenger seat cushioning member including the porous structure 1. Figure 6 In the illustrated part of the porous structure 1 , the skin portion 6 is formed flat, and can be formed in any shape along the outer surface of the skeleton portion 2 , for example, in a curved shape (curved surface shape).

[0132] like Figure 7 As shown, in this example, the epidermis portion 6 includes a plurality of through holes 6B, which penetrate the epidermis portion 6 in the thickness direction of the epidermis portion 6. The plurality of through holes 6B are distributed throughout the epidermis portion 6, so that the epidermis portion 6 is formed in a grid shape. Some or all (preferably all) of the through holes 6B of the epidermis portion 6 are not completely blocked by the bone portion 2B or the joint portion 2J of the skeleton portion 2 connected to the epidermis portion 6 to allow ventilation through the through holes 6B.

[0133] In this example, the epidermis 6 includes a plurality of columns 6C, each of which extends in a columnar shape along the outer surface of the skeleton 2 (more specifically, in this example, the epidermis 6 includes the columns 6C). The ends 6Ce of the columns 6C are connected at positions where the ends 6Ce of the plurality of columns 6C are adjacent to each other. Each through hole 6B is divided between the plurality of columns 6C. The columns 6C included in the epidermis 6 are not located in the skeleton 2.

[0134] The porous structure 1 includes the skin portion 6, and therefore, the skeleton portion 2 can be suppressed from being exposed to the outside of the porous structure 1 (i.e., the outside of the passenger seat cushion member). Therefore, when weight is applied to the passenger seat cushion member from a user or the like, the skeleton portion 2 does not directly bear the weight, but bears the weight via the skin portion 6, and therefore, the skeleton portion 2 is difficult to be damaged. As a result, the durability of the porous structure 1 (i.e., the passenger seat cushion member) can be improved.

[0135] In addition, the outer surface of the skin portion 6 is much less uneven than the outer surface of the frame portion 2, and the porous structure 1 includes the skin portion 6, which can reduce the user's discomfort when the user applies weight to the passenger seat cushioning member. As a result, the riding comfort of the passenger seat cushioning member can be improved.

[0136] Furthermore, since the skin portion 6 includes the plurality of through holes 6B, air permeability between the outside and the inside of the skeleton portion 2 can be ensured through the skin portion 6 .

[0137] However, when the skin portion 6 is arranged only in a portion of the outer surface of the skeleton portion 2 (i.e., included only in a portion of the outer surface of the passenger seat cushioning member), air permeability between the outer side and the inner side of the skeleton portion 2 can be ensured through the portion of the outer surface of the skeleton portion 2 where the skin portion 6 is not arranged (i.e., the portion of the outer surface of the passenger seat cushioning member where the skin portion 6 is not arranged). Therefore, the skin portion 6 does not necessarily have to include the through hole 6B. In other words, a continuous seat shape can be formed on the entire skin portion 6.

[0138] exist Figures 6 to 8 In the example of FIG. 5 , in the plan view of the skin portion 6 , the plurality of through holes 6B are arranged in a regular arrangement pattern, but the plurality of through holes 6B may be arranged randomly without regularity.

[0139] exist Figures 6 to 8 In the example of Figure 8In the surface view (in which the surface is viewed from a direction perpendicular to the outer surface of the epidermis portion 6), each column portion 6C extends linearly, and each through hole 6B has a triangular shape and is divided between three column portions 6C extending in mutually different directions. However, a part or all of each column portion 6C may extend in a curved shape (along a curved shape). Alternatively, in a plan view of the epidermis portion 6, each through hole 6B may have any polygonal shape (rectangular shape, etc.) other than a triangular shape, or any shape other than a polygonal shape (for example, a circle (a perfect circle, an ellipse, etc.)). In addition, in Figures 6 to 8 In the example of FIG. 5 , in a plan view of the skin portion 6 , the shape and size of each through hole 6B are uniform (same as one another), but the shape and / or size of each through hole 6B may be non-uniform.

[0140] exist Figures 6 to 8 In the example, the cross-sectional shape of each column 6C included in the epidermis 6 is a circle (a perfect circle). As a result, the structure of the epidermis 6 is simple, and the porous structure 1 (i.e., the passenger seat cushioning member) is easily formed by a 3D printer. In addition, there is no tip toward the outside of the porous structure 1, so the tactile comfort and riding comfort of the passenger seat cushioning member can be improved. Note that the cross-sectional shape of each column 6C is the shape of the cross section perpendicular to the extension direction of each column. However, the cross-sectional shape of each of all or part of the column 6C included in the epidermis 6 may be a polygonal shape (equilateral triangle, triangle other than equilateral triangle, rectangle, etc.), or may be a circle other than a perfect circle (ellipse, etc.). The cross-sectional shape of each bone portion 2B may be uniform along the extension direction, or may be non-uniform along the extension direction. The cross-sectional shapes of the column 6C may be different from each other.

[0141] As in Figures 6 to 8 In the example of FIG. 1 , when each through hole 6B of the epidermis portion 6 is divided by a plurality of pillar portions 6C, as in the example shown in the figure, the width W6C ( Figure 7 and Figure 8 ) may be uniform along the extension direction of the column portion 6C, or may be non-uniform along the extension direction of the column portion 6C. Alternatively, for the width W6C of each column portion 6C included in the epidermis portion 6, as in the illustrated example, the column portions 6C may have the same width as each other, or the column portions 6C may have different widths from each other. Note that the width W6C of each column portion 6C is the maximum width measured along the cross section in a cross section perpendicular to the extension direction of each column portion.

[0142] The maximum value of the width W6C of each column portion 6C included in the skin portion 6 is preferably 3.0 mm or less, more preferably 2.5 mm or less, to ensure the cushioning properties of the porous structural body 1 (i.e., the passenger seat cushioning member). The minimum value of the width W6C of each column portion 6C included in the skin portion 6 is preferably 0.05 mm or more, more preferably 0.10 mm or more, to improve the durability of the skin portion 6.

[0143] Similarly, the thickness T6 of the epidermis 6 ( Figure 7 ) may be uniform or non-uniform over the entire skin portion 6. The maximum value of the thickness T6 of the skin portion 6 is preferably 3.0 mm or less, more preferably 2.5 mm or less, to ensure the cushioning properties of the porous structural body 1 (i.e., the passenger seat cushioning member). The minimum value of the thickness T6 of the skin portion 6 is preferably 0.05 mm or more, more preferably 0.10 mm or more, to improve the durability of the skin portion 6.

[0144] In order to suppress damage to the skeleton portion 2, the maximum value of the diameter of each through hole 6B of the epidermis portion 6 (the diameter of the through hole 6B having the largest diameter) is preferably equal to or smaller than the average value of the diameter of each pore C of the skeleton portion 2, and more preferably smaller than the average value of the diameter of the pore C of the skeleton portion 2. Figure 8 In the example, when the shape of the through hole 6B in the plan view of the epidermal portion 6 is non-circular, the “diameter” of the through hole 6B in the plan view of the epidermal portion 6 is the diameter of the circumscribed circle of the through hole 6B.

[0145] As in Figures 6 to 8 In the example of , when each through hole 6B of the epidermal portion 6 is demarcated by a plurality of columnar portions 6C, in order to improve air permeability, the area ratio of the through holes 6B in the epidermal portion 6 is preferably 50% or more, and more preferably 70% or more. In addition, when each through hole 6B of the epidermal portion 6 is demarcated by a plurality of columnar portions 6C, in order to improve the durability of the epidermal portion 6, the area ratio of the through holes 6B in the epidermal portion 6 is preferably 99% or less, and more preferably 95% or less. Note that the "area ratio of the through holes 6B in the epidermal portion 6" represents the ratio of the total area A3 of all the through holes 6B arranged in the epidermal portion 6 to the entire area A2 of the epidermal portion 6 (A3×100 / A2[%]). The "entire area A2 of the epidermal portion 6" represents the area of ​​the portion surrounded by the outer edge of the epidermal portion 6, and also includes the area occupied by the through holes 6B.

[0146] Figures 9 to 11 It is an explanatory diagram of a second modification example of the porous structure 1 . Fig. 9 It is a perspective view showing a part of the second modification of the porous structure 1 . Fig.10 is shown along Fig. 9 Observed in the direction of arrow G (Y direction) Fig. 9A view of the portion F surrounded by a dotted line in the porous structure 1 as viewed from the perspective of arrow F. Fig.11 The diagram shows the observation along the direction of arrow H (-Z direction). Fig. 9 H arrow view of the G portion of the porous structure 1 in FIG.

[0147] In each example described in this specification, except Figure 1 In addition to the skeleton part 2 shown, the porous structure 1 may include Figures 6 to 8 In this case, the porous structure 1 may include or may not necessarily include the above-mentioned membrane 3 ( Figure 5 ).

[0148] Figures 9 to 11 In the example, the skin portion 6 is formed on at least a portion of the outer side of the skeleton portion 2 to block at least a portion of the plurality of pores C and to be integrated with the skeleton portion 2, and at least a portion of the outer side of the skin portion is a surface. When the porous structure 1 is used for a passenger seat cushioning member, the skin portion 6 is included in a portion or the entire outer surface of the passenger seat cushioning member including the porous structure 1. Fig. 9 In the illustrated part of the porous structure 1 , the skin portion 6 is formed flat, but the skin portion 6 may have any shape along the outer surface of the skeleton portion 2 , and may have, for example, a curved surface (curved shape).

[0149] exist Figures 9 to 11 In the example, the epidermis portion 6 includes a surface that is integrated with part or all of the outermost portion of the skeleton portion 2 and is continuous to block part or all of the bubble pores C. At least a portion of the outer side of the epidermis portion 6 is a surface. Here, the "surface" is, for example, a roughly smooth and continuous surface and may be a smooth surface without bumps or a surface with bumps. However, when the surface has bumps, the surface preferably has a surface roughness that allows forming by using a 3D printer, for example, such a surface roughness is such that the dimensions of the convex and concave portions of the bumps in each direction (such as height, depth, width, and diameter, etc.) are 0.1 mm or more, and the height of each convex portion of the bumps (in other words, the depth of each concave portion) is preferably 2 mm or less.

[0150] Therefore, since the skin portion 6 is formed in at least a portion of the outer side of the frame portion 2 to block at least a portion of the plurality of pores C, the discomfort felt by the user when the user applies weight to the passenger seat cushioning member can be reduced. As a result, the riding comfort of the passenger seat cushioning member can be improved.

[0151] exist Figures 9 to 11 In the example, the epidermis portion 6 includes a smooth portion 6A, the surface of the epidermis portion 6 is formed at the smooth portion 6A, and the through-hole 6B is defined by the smooth portion 6A and penetrates the epidermis portion 6 .

[0152] The ratio of the area of ​​the outer surface of the smooth portion 6A (i.e., the surface area of ​​the smooth portion 6A) to the area of ​​the outer surface of the epidermis portion 6 (i.e., the surface area of ​​the epidermis portion 6) is preferably 8% or more. The surface area of ​​the epidermis portion 6 is the sum of the surface area of ​​the smooth portion 6A and the total area of ​​the opening of the through hole 6B.

[0153] When the ratio of the surface area of ​​the smooth portion 6A to the surface area of ​​the epidermis 6 is 8% or more, the pressure on the smooth portion 6A when the porous structure 1 is compressed increases. Therefore, the portion of the skeleton 2 directly impacted is reduced, and the skeleton 2 is hardly damaged. Therefore, the durability of the porous structure 1 is improved. However, the ratio of the surface area of ​​the smooth portion 6A to the surface area of ​​the epidermis 6 may be less than 8%. In this case, the air permeability between the outside and the inside of the skeleton 2 in the porous structure 1 can be further improved.

[0154] Each through hole 6B may have a circular or oblong opening shape in a surface view, or may have a rectangular shape or any other shape. In this example, the epidermis 6 includes a plurality of through holes 6B, and the plurality of through holes 6B are arranged so that the surface of the epidermis 6 is continuous in a lattice shape in a surface view.

[0155] As described above, the passenger seat cushion member of the present disclosure may be any kind of passenger seat cushion member, and is preferably, for example, a vehicle seat cushion member, and more preferably, a car seat cushion. As an example of the passenger seat cushion member, a car seat cushion will be described below.

[0156] As an example, Fig.12 Shown include Figure 1 An automobile seat pad (passenger seat cushion member) 300 of the porous structure 1 of the example. Fig.12 The car seat cushion in the example of EMBODIMENT 3 includes a cushion pad 310 for a seat occupant to sit on and a backrest pad 320 for supporting the back of the seat occupant.

[0157] exist Fig.12 , “up”, “down”, “left”, “right”, “front”, and “rear” directions when viewed from a seated person sitting on the car seat cushion 300 are shown.

[0158] The cushion pad 310 includes a main pad 311 on which the seated person's hip area and thigh area are seated, and a pair of side pads 312 located on the left and right sides of the main pad 311. The backrest pad 320 includes a main pad 321 configured to support the seated person's back and waist, and a pair of side pads 322 located on the left and right sides of the main pad 321.

[0159] exist Fig.12In the example of FIG. 1 , the cushion pad 310 and the backrest pad 320 each include a separate porous structure (as a separate member). The porous structure included in a portion of the cushion pad 310 (the filler body 8 to be described in detail later) is a porous structure in reference to FIG. Figures 1 to 11 In each of the examples described, the porous structure 1 formed by the 3D printer, the porous structure included in the remaining part is formed by a chemical reaction foaming process during molding, etc. In addition, the porous structure included in the back pad 320 is formed by a chemical reaction foaming process during molding, etc. Therefore, for example, only a part of the cushion pad 310 and the back pad 320 is manufactured by the 3D printer, so the cost can be reduced.

[0160] Fig.13 3 is a perspective view showing in detail the main pad 311 and the side pad 312 of the cushion pad 310. Fig.13 As shown, the main cushion 311 includes a seat body 7 and a filling body 8 filling the seat body 7 .

[0161] Here, refer to Figures 14 to 17 An example of the seat main body 7 will be described in detail. Fig.14 It is shown Fig.13 A three-dimensional view of the seat body 7 in the main pad 311. Fig.15 It is shown Fig.14 A top view of the seat body 7 in FIG. Fig.16 yes Fig.14 II sectional view of the middle seat body 7. Fig.17 yes Fig.14 JJ cross-sectional view of the seat body 7 in FIG.

[0162] like Fig.14 As shown, the seat body 7 includes a buttocks lower portion 71, a leg lower peripheral portion 72, a groove portion 73, a hole portion 74, a backrest pad connection portion 75, and a seat body side connection portion 76. The buttocks lower portion 71, the leg lower peripheral portion 72, and the backrest pad connection portion 75 include a porous structure manufactured by a foaming process of a chemical reaction during molding or the like.

[0163] The buttocks lower portion 71 has a generally flat surface facing upward. Fig.15 As shown, in a plan view of the surface on which the seated person sits viewed from the seated person's side, the lower buttocks portion 71 has a shape whose periphery is formed by three straight lines located at the rear, left and right sides and a gentle convex arc-shaped curve located at the front side.

[0164] In a plan view, the leg-under-circumference portion 72 is arranged on the front side of the front curve constituting the periphery of the buttock-under portion 71. The leg-under-circumference portion 72 defines a hole portion 74 having a substantially rectangular shape and extending in the up-down direction on the inner side of the leg-under-circumference portion 72. Fig.14 and Fig.15In the example of FIG. 1 , the hole portion 74 penetrates the seat body 7 in the up-down direction, or the hole portion 74 may have a concave shape having a bottom surface on the upper side or the lower side.

[0165] In a top view, the leg lower peripheral edge portion 72 has a shape whose periphery is formed by two straight lines located on the left and right sides and facing each other, and gently arcuate curves located on the front and rear sides. The gently arcuate curves located on the rear side of the leg lower peripheral edge portion 72 are positioned at constant intervals along the curve constituting the periphery of the lower buttocks portion 71.

[0166] exist Figures 14 to 17 In the example of FIG. 1 , the leg lower peripheral edge portion 72 includes a lower leg lower peripheral edge portion (first leg lower peripheral edge portion) 721, an upper leg lower peripheral edge portion (second leg lower peripheral edge portion) 722, and a front leg lower peripheral edge portion (third leg lower peripheral edge portion) 723. The lower leg lower peripheral edge portion 721, the upper leg lower peripheral edge portion 722, and the front leg lower peripheral edge portion 723 are integrated with each other. The lower leg lower peripheral edge portion 721, the upper leg lower peripheral edge portion 722, and the front leg lower peripheral edge portion 723 are also integrated with the side pad 312.

[0167] The lower leg lower peripheral edge portion 721 and the upper leg lower peripheral edge portion 722 are located on the left, right and rear sides of the leg lower peripheral edge portion 72 in a top view. The lower leg lower peripheral edge portion 721 is located below the upper leg lower peripheral edge portion 722 and protrudes inward from the upper leg lower peripheral edge portion 722. Fig.16 As shown, the left side 721L of the lower leg lower peripheral portion 721 protrudes to the right side at the left side 722L of the upper leg lower peripheral portion 722, and the right side 721R of the lower leg lower peripheral portion 721 protrudes to the left side at the right side 722R of the upper leg lower peripheral portion 722. Fig.17 As shown, the rear side 721B of the lower leg lower peripheral edge 721 protrudes forward from the rear side 722B of the upper leg lower peripheral edge 722. Therefore, a main body step surface BS is formed at the lower leg lower peripheral edge 721 as a step surface along the up-down direction and continuous with the inner side surface of the upper leg lower peripheral edge 722.

[0168] like Fig.17 As shown, the front leg lower peripheral edge portion 723 is located at the front side in the entire leg lower peripheral edge portion 72. Fig.16 As shown, the upper end portion 723T of the front leg lower peripheral edge portion 723 is located at the lowest position near the center in the left-right direction and is located at a higher position as it moves toward the end in the left-right direction.

[0169] like Fig.14 and Fig.15As shown, the groove 73 is a groove defined by the rear curve constituting the periphery of the lower leg peripheral edge portion 72 and the front curve constituting the periphery of the lower buttocks portion 71 in a plan view. The groove 73 can accommodate the seam allowance of the cover on the cushioning member 300.

[0170] The back pad connecting portion 75 is connected to the lower buttocks portion 71 and may be connected to the back pad 320 .

[0171] The seat body side connecting portion 76 includes a mechanical connecting means for connecting to the filling body 8. The connecting means referred to as the mechanical connecting means is not a chemical connecting means using an adhesive or the like. Figures 13 to 20 In the example of , the mechanical connection means is a hook and loop fastener (seat body side hook and loop fastener) arranged on the outer surface of the seat body 7. Figures 13 to 20 In the example of , the seat body side connecting portion 76 is installed so that the removable mounting surface of the seat body side hook and loop fastener faces the opposite side of the leg lower peripheral edge portion 72, in other words, faces the hole portion 74 side. The removable mounting surface includes, for example, a plurality of micro hooks or loops. Note that when the seat body side hook and loop fastener includes a plurality of micro hooks, the filler body side hook and loop fastener 822 described later includes micro loops. When the seat body side hook and loop fastener includes a plurality of micro loops, the filler body side hook and loop fastener 822 described later includes a plurality of micro hooks. When the seat body side hook and loop fastener includes both a plurality of micro hooks and a plurality of micro loops, the filler body side hook and loop fastener 822 described later includes both a plurality of micro hooks and a plurality of micro loops.

[0172] The seat body side connection part 76 includes at least one of a lower seat body side connection part 761 and an upper seat body side connection part 762 (in Figures 14 to 17 In the example, the seat body side connection portion 76 includes a lower seat body side connection portion 761 and an upper seat body side connection portion 762. The lower seat body side connection portion 761 is attached to at least a portion of the inner surface of the lower leg lower peripheral portion 721 (at Figures 14 to 17 In the example, the lower seat body side connecting portion 761 is mounted to the entire inner surface of the lower leg lower peripheral edge portion 721). The upper seat body side connecting portion 762 is mounted to at least a portion of the inner surface of the upper leg lower peripheral edge portion 722 (in Figures 14 to 17 In the example of FIG. 1 , the upper seat body side connecting portion 762 is mounted to the entire inner surface of the upper leg lower peripheral edge portion 722).

[0173] Then, refer to Figures 18 to 20 An example of the filling body 8 will be described in detail. Fig.18 It is shown Fig.13 A three-dimensional view of the filling body 8 in the main pad 311. Fig.19 yes Fig.18 KK cross-sectional view of the filling body 8 in FIG. Fig. 20 yes Fig.18LL cross-sectional view of the filler body 8 in FIG. Note that the skeleton portion 2 is omitted. Figures 18 to 20 Only the outer shape of the porous structure 1 is shown. The porous structure 1 is formed by a 3D printer and corresponds to the reference Figures 1 to 11 A porous structure 1 is one example of each of the described examples.

[0174] The filling body 8 includes a main body 81 including a porous structure made of a flexible resin or rubber and a filling body side connecting portion 82, which is arranged adjacent to the main body 81 and includes a mechanical connection means connected to the seat body side connecting portion 76, and at least a part of the filling body side connecting portion 82 includes a porous structure. The main body 81 is integrated with the seat body side connecting portion 76. Figures 18 to 20 In the example of , the filling body side connecting portion 82 partially includes the porous structure 1 .

[0175] exist Figures 18 to 20 In the example of FIG. 1 , the main body 81 includes a first main body 811 and a second main body 812 that is integrated with the first main body 811. The second main body 812 is arranged in a seating direction ( Figures 18 to 20 In the downward direction shown in the figure, it is adjacent to the first main body portion 811 and is integrated with the first main body portion 811.

[0176] The mechanical connection means in the filling body side connection part 82 is a filling body side hook and loop fastener 822 (hook and loop fastener) arranged on the outside of the main body part 81. Specifically, the filling body side connection part 82 includes an outer edge part 821 arranged in at least a part of the outer edge of the main body part 81 and including the porous structural body 1, and the filling body side hook and loop fastener 822 mounted to the outer edge part 821. The outer edge part 821 is arranged in at least a part of the outer edge included in the front and rear sides and the left and right sides of the main body part 81 and at a position facing the seat body side connection part 76.

[0177] For example, the outer edge portion 821 includes at least one of a first outer edge portion 8211 and a second outer edge portion 8212 (in Figures 18 to 20 In the example, the outer edge portion 821 includes both a first outer edge portion 8211 and a second outer edge portion 8212. The first outer edge portion 8211 is arranged in at least a portion of the outer edge on the rear, left and right sides of the first main body portion 811 and faces the lower seat body side connecting portion 761 (at Figures 18 to 20 In the example of FIG. 1 , the first outer edge portion 8211 is arranged on each of the rear side, left side, and right side of the first main body portion 811). The second outer edge portion 8212 is arranged in a position (at the position of the upper seat body side connecting portion 762) that is included in at least a portion of the outer edge on the rear side, left side, and right side of the second main body portion 812 and faces the upper seat body side connecting portion 762. Figures 18 to 20In the example of FIG. 8 , the second outer edge portion 8212 is arranged on each of the rear side, the left side, and the right side of the second main body portion 812 ).

[0178] When the portion of the porous structure 1 included in each of the first main body portion 811 and the first outer edge portion 8211 corresponds to the first porous structure 11 and the portion of the porous structure 1 included in each of the second main body portion 812 and the second outer edge portion 8212 corresponds to the second porous structure 12, the second porous structure 12 is arranged in a direction opposite to the seating direction ( Figures 18 to 20 The first porous structure 11 protrudes in a direction perpendicular to the downward direction shown in FIG. Fig.19 As shown, the second porous structure 12 is arranged to protrude beyond the first porous structure 11 in the left-right direction. Fig. 20 As shown, the second porous structural body 12 is arranged to protrude beyond the first porous structural body 11 in the front-rear direction.

[0179] By this configuration, a step surface PS is formed at the second porous structure 12, which is a step surface facing the downward direction and continuous with the first porous structure 11. In addition, the porous structure 1 is formed so that the step surface PS extends along the main body step surface BS of the seat main body 7 described above (see Fig.16 and Fig.17 ).

[0180] As a result, when the filling body 8 is inserted downward from above the hole portion 74 in such a manner that the first main body portion 811 is below the second main body portion 812, the protruding portion of the second porous structure 12 beyond the first porous structure 11 is locked by the main body step surface BS, and the porous structure 1 can be positioned in the up-down direction in the hole portion 74 of the seat main body 7. Therefore, the filling body 8 including the porous structure 1 is stably arranged, and therefore, the car seat pad 300 can be easily manufactured.

[0181] In addition, Figures 18 to 20 In the example of FIG. 8 , the lower end of the forward protruding portion of the second main body portion 812 is bent to be lowest near the center in the left-right direction and to be higher and higher as it goes toward the end in the left-right direction. Fig.16 and Fig.17 The upper end portion 723T of the lower peripheral edge portion 723 of the front leg shown is bent along a curved shape. Therefore, the porous structure 1 is arranged to be wider than the left and right ends near the center in front of the main pad 311. As described above, the second main body portion 812 includes the porous structure 1, and the porous structure 1 is formed by a 3D printer. Therefore, the forward protruding portion of the second main body portion 812 can have a characteristic that makes the back of the knee and the calf of the seated person feel comfortable. As a result, the seated person can sit comfortably.

[0182] The filler-body-side hook-and-loop fastener 822 is mounted on the opposite side of the main body portion 81 in the outer edge portion 821 in such a manner that the removable mounting surface of the filler-body-side hook-and-loop fastener 822 faces outward. At this time, the filler-body-side hook-and-loop fastener 822 is mounted to the outer edge portion 821 by bonding its surface opposite to the removable mounting surface to the outer edge portion 821 with an adhesive. The filler-body-side hook-and-loop fastener 822 is engaged with the seat-body-side hook-and-loop fastener of the seat-body-side coupling portion 76 described above, and thus the filler 8 is coupled to the seat body 7.

[0183] Specifically, the filler side hook and loop fastener 822 includes at least one of a filler side first hook and loop fastener 8221 and a filler side second hook and loop fastener 8222 (in Figures 18 to 20 In the example, the filler side hook and loop fastener 822 includes a filler side first hook and loop fastener 8221 and a filler side second hook and loop fastener 8222 .

[0184] The first hook and loop fastener 8221 on the filling body side is installed to a position included in at least a portion of the outer side of the first outer edge portion 8211 (in other words, the opposite side of the first main body portion 811) and facing the lower seat body side connecting portion 761, so that the removable installation surface of the first hook and loop fastener 8221 on the filling body side faces the outer side (on the opposite side of the first main body portion 811). Figures 18 to 20 In the example of FIG. 1 , the first hook-and-loop fastener 8221 on the filler body side is mounted on each of the rear side, the left side, and the right side of the first outer edge portion 8211). At this time, the first hook-and-loop fastener 8221 on the filler body side is mounted to the first outer edge portion 8211 by bonding the surface of the fastener opposite to the removable mounting surface to the first outer edge portion 8211 with an adhesive. The second hook-and-loop fastener 8222 on the filler body side is mounted to a position included in at least a portion of the outer side of the second outer edge portion 8212 (in other words, the opposite side of the second main body portion 812) and facing the upper side seat main body side connecting portion 762, so that the removable mounting surface of the second hook-and-loop fastener 8222 on the filler body side faces the outer side (on the opposite side of the second main body portion 812). Figures 18 to 20 In the example of FIG. 1 , the filler-side second hook-and-loop fastener 8222 is mounted on each of the rear side, the left side, and the right side of the second outer edge portion 8212). At this time, the filler-side second hook-and-loop fastener 8222 is mounted to the second outer edge portion 8212 by bonding the surface of the fastener opposite to the removable mounting surface to the second outer edge portion 8212 with an adhesive.

[0185] Therefore, the filling body side connecting portion 82 including the filling body side hook and loop fastener 822 in the filling body 8 is engaged with the seat body side connecting portion 76 including the seat body side hook and loop fastener. As a result, the filling body 8 can be arranged more easily to fill the seat body 7 than in the case where the filling body 8 is chemically bonded to the seat body 7 by using, for example, an adhesive or the like. The filling body side hook and loop fastener 822 and the seat body side fastener engaged with each other can thus be easily separated from each other, and therefore, the filling operation can be easily performed again so that the filling body 8 is filled in the correct position in the seat body 7.

[0186] The density of the portion of the filling body side coupling portion 82 including the porous structural body 1 (in this example, the outer edge portion 821 ) is higher than the density of the main body portion 81 . Here, the density is the mass per unit volume of the porous structural body 1 .

[0187] Preferably, the region from the outermost surface of the porous structural body 1 to a position 2 mm to 10 mm from the outermost surface is a region (outer edge portion 821) where the density of the filler-side connecting portion 82 is higher than the density of the main body portion 81. In this case, preferably, the density of the outer edge portion 821 is 1 to 5 times the density of the main body portion 81.

[0188] In order to set the density of the outer edge portion 821 to be higher than the density of the main body portion 81, the number of bone portions 2B per unit area in the outer edge portion 821 may be greater than the number of bone portions 2B per unit area in the main body portion 81, and the average cross-sectional area of ​​the bone portions 2B in the outer edge portion 821 may be greater than the average cross-sectional area of ​​the bone portions 2B in the main body portion 81. In addition, as a material forming the bone portions 2B of the outer edge portion 821, a material having a higher density than the material forming the bone portions 2B of the main body portion 81 may be used.

[0189] When the porous structure 1 including the main body 81 and the outer edge 821 arranged adjacent to each other and integrated as described above is formed by a process of chemical reaction foaming during conventional molding, etc., it is difficult to set the number of bone portions 2B in the main body and the cross-sectional area of ​​each bone portion 2B to be different from those in the outer edge. However, when a 3D printer is used, as described in detail later, the porous structure 1 is formed by using a computer based on three-dimensional shape data (e.g., three-dimensional CAD data) representing the three-dimensional shape of the porous structure 1. Therefore, it is easy to form a porous structure 1 including the outer edge 821 and the main body 81, the number of bone portions 2B per unit area of ​​the outer edge 821 and the main body 81 and the cross-sectional area of ​​each bone portion 2B are different and are arranged adjacent to each other and integrated. As a result, the filling body 8 including the porous structure 1 can be easily manufactured.

[0190] Therefore, the outer edge portion 821 included in the filling body side coupling portion 82 facing the seat body 7 is formed to be difficult to bend while maintaining the cushioning property in the main body portion 81 including the portion where the seat occupant sits, so that the filling body 8 can be firmly and easily mounted to the seat body 7. Therefore, the automobile seat pad (passenger seat cushion member) 300 including the filling body 8 firmly mounted to the seat body 7 can be easily manufactured.

[0191] Therefore, the density of the portion (in this example, the outer edge portion 821) including the porous structure 1 in the filling body side connecting portion 82 is set to be higher than the density of the main body portion 81, so that when an external force is applied to the skeleton portion 2 of the porous structure 1 included in the outer edge portion 821, the reaction force generated by the skeleton portion 2 (in other words, the hardness of the skeleton portion 2 (i.e., the porous structure 1)) can be favorable to the extent that the filling body can be easily and firmly connected to the seat body 7. In other words, the outer edge portion 821 can be appropriately difficult to bend to the extent that the filling body 8 including the outer edge portion 821 included in the filling body side connecting portion 82 facing the seat body 7 can be easily and firmly installed to the seat body 7. In this case, the filling body 8 including the porous structure 1 can be easily and firmly installed.

[0192] In addition, when an external force is applied to the skeleton portion 2 of the porous structural body 1 included in the main body portion 81, the reaction force generated by the skeleton portion 2 (in other words, the hardness of the skeleton portion 2 (i.e., the porous structural body 1)) can be advantageous to the extent that the cushioning characteristics when the seat occupant sits are excellent. In this case, the comfort of the seat occupant when sitting on the main body portion 81 facing the seat occupant can be improved, and the seat occupant can sit comfortably.

[0193] Here, refer to Figure 21 to Figure 23 A modification example of the filling body 8 of the automobile seat pad 300 as the passenger seat cushion member of the present disclosure will be described. Fig.21 It is shown Fig.18 A three-dimensional view of a modified example of the filling body 8 in FIG. Fig. 22 yes Fig.21 MM cross-sectional view of the filling body 8 in. Fig.23 yes Fig.21 NN cross-sectional view of the filling body 8 in FIG.

[0194] Figure 21 to Figure 23 At least a portion of the filler body 8 comprises Figures 9 to 11 That is, at least one of the porous structure 1 included in the main body 81 and the porous structure 1 included in the outer edge 821 includes Figures 9 to 11In the example of the epidermis 6, the epidermis 6 is integrated with the skeleton 2 in at least a portion of the outer side of the skeleton 2 of the porous structure 1. Specifically, the porous structure 1 included in the main body 81 includes the epidermis 6 located on the outer side of the main body 81, and the epidermis 6 does not face the outer edge 821. Figure 21 to Figure 23 In the example of , the porous structure 1 included in the main body portion 81 includes the skin portion 6 located on the upper side of the second main body portion 812. As a result, when the seat occupant sits on the car seat pad 300, the skeleton portion 2 of the porous structure 1 included in the main body portion 81 does not face the seat occupant, but the skin portion 6 faces the seat occupant. This can prevent the corner formed by the skeleton portion 2 from contacting the seat occupant, and the seat occupant can sit comfortably.

[0195] In addition, at least a portion of the epidermis 6 of the porous structure 1 included in the main body 81 may include the smooth portion 6A and the through-holes 6B in the same manner as in the epidermis 6 of the porous structure 1 described above. Figure 21 to Figure 23 In the example of , the skin portion 6 located at the lower side of the first body portion 811 and the upper side of the second body portion 812 in the porous structure 1 included in the body portion 81 includes a smooth portion 6A and a through hole 6B. As a result, the air permeability between the outer side and the inner side of the skin portion 6 in the porous structure 1 can be improved. Therefore, the air permeability of the portion where the seated person sits can be improved, and the seated person can sit comfortably.

[0196] The porous structure 1 included in the outer edge portion 821 includes a skin portion 6 located outside the outer edge portion 821, that is, on the side facing the seat body 7. Figure 21 to Figure 23 In the example of , the porous structure 1 included in the outer edge portion 821 includes the skin portion 6 located on the outer side of the outer edge portion 821 (i.e., the right side of the right outer edge portion 821, the left side of the left outer edge portion 821, and the rear side of the rear outer edge portion 821). As a result, for example, when the filler-side hook and loop fastener 822 is bonded and mounted to the outer edge portion 821 via an adhesive, the bonding area between the filler-side hook and loop fastener 822 and the outer edge portion 821 is larger than the bonding area when the porous structure 1 included in the outer edge portion 821 does not include the skin portion 6, and therefore, the filler-side hook and loop fastener 822 can be firmly bonded to the outer edge portion 821.

[0197] In addition, at least a portion of the skin portion 6 of the porous structure 1 included in the main body 81 does not necessarily include the through-holes 6B, similarly to the skin portion 6 of the porous structure 1 described above, but may include only the smooth portion 6A. Figure 21 to Figure 23In the example of , the epidermis 6 of the porous structure 1 included in the outer edge portion 821 does not include the through hole 6B, but includes only the smooth portion 6A. When the epidermis 6 in the porous structure 1 included in the main body 81 does not include the through hole 6B, the bonding area between the filler-side hook and loop fastener 822 and the outer edge portion 821 is larger than the bonding area when the epidermis includes the through hole 6B, and therefore, the filler-side hook and loop fastener 822 can be more firmly bonded to the outer edge portion 821.

[0198] In addition, as described above, at least a portion of the surface (outer surface) of the epidermis portion 6 may be a curved surface. Figure 21 to Figure 23 In the example, Fig.23 As shown, the outer surface of the epidermis part 6 in the surface of the forward protruding part of the second main body part 812 is a curved surface that is smoothly curved so that the central part in the up-down direction of the outer surface protrudes more forward than the upper and lower parts of the outer surface. As a result, when the seat occupant sits on the car seat pad 300 provided with the porous structure 1, the front curved surface of the second main body part 812 extends along the back of the knee and the calf of the seat occupant, and the corner of the porous structure 1 can be prevented from contacting the seat occupant. Therefore, the seat occupant can sit comfortably.

[0199] Alternatively, Figure 21 to Figure 23 The porous structure 1 included in the filling body 8 of the main pad 311 in the car seat pad 300 in the example may be Figures 6 to 8 More specifically, in the example of the porous structure 1 Figure 21 to Figure 23 In the modified example, the filling body 8 of the main pad 311 in the car seat cushion 300 includes Figures 9 to 11 The epidermal portion 6 in the example of Figures 6 to 8 The epidermis portion 6 in the example.

[0200] As a result, when a seat occupant sits on the car seat pad 300, the skeleton portion 2 of the porous structural body 1 included in the main body portion 81 does not face the seat occupant, but Figures 6 to 8 The skin portion 6 in the seated portion faces the seated person. Therefore, the corners of the frame portion 2 can be prevented from contacting the seated person, and the seated person can sit comfortably. In addition, for example, when the filler-side hook-and-loop fastener 822 is bonded and mounted to the outer edge portion 821 via an adhesive, the bonding area between the filler-side hook-and-loop fastener 822 and the outer edge portion 821 is larger than the bonding area when the porous structure 1 included in the outer edge portion 821 does not include the skin portion 6, and therefore, the filler-side hook-and-loop fastener 822 can be firmly bonded to the outer edge portion 821.

[0201] Here, refer to Fig.24 and Fig.25 A first modification example of a main pad 311 in a cushion pad 310 of a vehicle seat pad 300 as a passenger seat cushion member according to the present disclosure will be described. Fig.24 is corresponding to Fig.13 , and is a perspective view showing a first modification example of the cushion pad and the side pad in detail. Fig.25 yes Fig.24 An enlarged top view of section P in FIG.

[0202] The mechanical connection means in the seat body side connection part 76 is a recessed part formed in the seat body 7. Fig.24 and Fig.25 In the example of , the seat body side connection portion 76 of the seat body 7 is formed as a recess of the leg lower peripheral portion 72 communicating with the hole portion 74. In the present example, the seat body side connection portion 76 is constituted only by a recess as a mechanical connection means. In the present example, the leg lower peripheral portion 72 includes the seat body side connection portion 76 in an area located behind the hole portion 74, but the present disclosure is not limited to this example, and the seat body side connection portion 76 may be arranged in at least one area located behind, in front of, and to the side of the hole portion 74. In addition, in the present example, the leg lower peripheral portion 72 includes two seat body side connection portions 76, but the present disclosure is not limited to this example, and the leg lower peripheral portion may include one seat body side connection portion 76 or three or more seat body side connection portions 76.

[0203] The mechanical connection means in the filling body side connection part 82 is formed as a convex part protruding from the main body part 81. In this example, the filling body side connection part 82 is composed only of the convex part as the mechanical connection means. In this example, the filling body side connection part 82 formed as a convex part protruding from the main body part 81 is inserted and wedge-fitted into the seat body side connection part 76 formed as a concave part in the seat body 7, so that the filling body side connection part 82 is connected to the seat body side connection part 76. In this example, the entire filling body side connection part 82 includes the porous structure 1. Wedge-fitting means that one component is fit into another component and then geometrically prevented from falling off from the other component.

[0204] In this example, in the top view, in the filling body side connecting portion 82 (that is, the convex portion as the mechanical connecting means), the filling body side connecting portion 82 is Fig.24 and Fig.25 In the example of the front-rear direction, the position P1 is perpendicular to the protruding direction ( Fig.24 and Fig.25 The length L1 in the left-right direction in the example is longer than the length L2 of the seat body side connecting portion 76 in the direction orthogonal to the protruding direction at least at position P2 (position P2 is closer to the main body 81 in the protruding direction than position P1), and the protrusion other than the root side portion is formed into a roughly cylindrical shape or a roughly spherical shape extending in the up and down direction.

[0205] exist Fig.24 and Fig.25In the example, the length in the left-right direction of the filling body side connecting portion 82 (i.e., the convex portion as a mechanical connecting means) increases from the rear side end portion 82a of the filling body side connecting portion 82 to the position P1 as it approaches the main body portion 81, decreases from the position P1 to the position P2 as it approaches the main body portion 81, and increases again from the position P2 to the boundary position P3 between the filling body side connecting portion 82 and the main body portion 81 as it approaches the main body portion 81. However, the present disclosure is not limited to this example, and the filling body side connecting portion 82 may be formed into a shape including two positions in the front-to-back direction, wherein, when the lengths in the left-right direction at the positions are compared, the left-right direction length at the position located on the rear side is longer than the left-right direction length at the position located on the front side.

[0206] exist Fig.24 and Fig.25 In the example of , the shape of the seat body side connection part 76 (i.e., the concave part as the mechanical connection means) is substantially the same as the shape of the filling body side connection part 82 (i.e., the convex part as the mechanical connection means). As a result, the left-right length of the seat body side connection part 76 at position P2 is shorter than the left-right length of the filling body side connection part 82 at position P1, so that the above-mentioned concave part and convex part can be wedge-fitted with each other.

[0207] Note that, in view of the density of the seat body 7 in the peripheral portion of the seat body side connecting portion 76 and the density of the filling body side connecting portion 82, the left-right length of the filling body side connecting portion 82 at the position P1 and the left-right length of the seat body side connecting portion 76 at the position P2 are determined so that the filling body side connecting portion 82 is not easy to fall off from the seat body side connecting portion 76 in the forward direction.

[0208] In this configuration, the filling body side coupling portion 82 is moved downward from the top and inserted into the seat body side coupling portion 76, and the main body portion 81 is inserted into the hole portion 74, so that the filling body 8 fills the hole portion. The filling body side coupling portion 82 is inserted into the seat body side coupling portion 76, and the position of the filling body side coupling portion 82 in the front-rear direction and the left-right direction is restricted so as to position the main body portion 81 in the hole portion 74. As a result, the filling body 8 can be correctly and easily installed to fill the seat body 7. Therefore, the car seat pad 300 can be correctly and easily manufactured.

[0209] In addition, as described above, the filling body side connecting portion 82 has a Fig.25 The front-rear direction in the example of FIG. 1 is a direction perpendicular to the protruding direction ( Fig.25The length L1 in the left-right direction (in the example of the left-right direction) is longer than the length L2 in the direction orthogonal to the protruding direction at least at the position P2 of the seat body side connecting portion 76 in the protruding direction (the position P2 is closer to the main body 81 than the position P1), so that the filling body side connecting portion 82 can be prevented from moving in the front-back direction and falling off from the seat body side connecting portion 76. As a result, the filling body 8 can be prevented from moving in the front-back direction and falling off from the seat body 7, and the automobile seat pad 300 with high firmness can be manufactured.

[0210] In addition, the density of the portion including the porous structural body 1 in the filling body side connecting portion 82 (in this example, the filling body side connecting portion 82 itself is a convex portion as a mechanical connecting means) is higher than the density of the main body 81. Specifically, the density of a part or the entire convex portion is increased so that the density of the (entire) convex portion can be higher than the density of the main body 81. In this case, the density of the (entire) convex portion can be 1 to 5 times the density of the main body 81.

[0211] In order to set the density of the convex portion higher than that of the main body portion 81, the number of bone portions 2B per unit area in the convex portion may be greater than the number of bone portions 2B per unit area in the main body portion 81, or the average cross-sectional area of ​​the bone portions 2B in the convex portion may be greater than the average cross-sectional area of ​​the bone portions 2B in the main body portion 81. A material having a higher density than the density of the material forming the bone portions 2B included in the main body portion 81 may be used as the material forming the bone portions 2B included in the convex portion.

[0212] As described above, the porous structure 1 including the outer edge portion 821 and the main body portion 81, which are arranged adjacent to each other and become one body and the number of bone portions 2B per unit area and the cross-sectional area of ​​the bone portion 2B are different from each other in the porous structure 1, can be easily formed by using a 3D printer. Therefore, the filling body 8 including the porous structure 1 can be easily manufactured.

[0213] Therefore, the filling body side connecting portion 82 facing the seat main body 7 is difficult to bend while maintaining the cushioning properties of the main body portion 81 including the seated portion of the seat occupant, so that the filling body 8 can be firmly and easily mounted to the seat main body 7. Therefore, the automobile seat pad (passenger seat cushion member) 300 including the filling body 8 firmly mounted to the seat main body 7 can be easily manufactured.

[0214] Therefore, the density of the portion including the porous structure 1 in the filling body side connecting portion 82 (in this example, the filling body side connecting portion 82 itself is a convex portion as a mechanical connecting means) is higher than the density of the main body portion 81, so that when an external force is applied to the skeleton portion 2 of the porous structure 1 included in the convex portion, the reaction force generated by the skeleton portion 2 (in other words, the hardness of the skeleton portion 2 (i.e., the porous structure 1)) can be favorable to the extent that the filling body can be easily and firmly connected to the seat main body 7. In this case, the filling body 8 including the porous structure 1 can be easily and firmly installed.

[0215] In addition, the reaction force generated on the skeleton part 2 when an external force is applied to the skeleton part 2 of the porous structural body 1 included in the main body part 81 (in other words, the hardness of the skeleton part 2 (i.e., the porous structural body 1)) can be advantageous to the extent that the cushioning characteristics when the seat occupant sits are excellent. In this case, the comfort of the seat occupant when sitting on the main body part 81 can be improved, and the seat occupant can sit comfortably.

[0216] Here, refer to Fig.26 and Fig. 27 A second modification example of the main pad 311 in the cushion pad 310 of the automobile seat pad 300 as the passenger seat cushion member according to the present disclosure will be described. Fig.26 is corresponding to Fig.13 , and is a perspective view showing a second modified example of the main pad and the side pad in detail. Fig. 27 yes Fig.26 This is an enlarged top view of section Q in FIG. Fig.26 and Fig. 27 In the example, Fig.24 and Fig.25 Similarly to the example of the seat body 7, the seat body side connecting portion 76 of the seat body 7 is formed as a recessed portion of the leg lower peripheral portion 72 to communicate with the hole portion 74. The filling body side connecting portion 82 is formed as a member protruding from the main body portion 81. In this example, the entire filling body side connecting portion 82 includes the porous structure 1. In addition, in this example, Fig.24 and Fig.25 Similarly, the filler body side connecting portion 82 formed as a convex portion protruding from the main body portion 81 is inserted and wedge-fitted into the seat body side connecting portion 76 formed as a concave portion in the seat body 7, so that the filler body side connecting portion 82 is connected to the seat body side connecting portion 76.

[0217] exist Fig. 27 In the example of FIG. 1 , the seat body side connecting portion 76 partially does not have a shape substantially the same as the shape of the filling body side connecting portion 82, but has a shape that can accommodate the filling body side connecting portion 82. The left-right length L4 of the seat body side connecting portion 76 between the position P4 and the boundary position P5 is shorter than the left-right length L3 of the filling body side connecting portion 82 at the position P4. Fig. 27 In the example, the length of the filling body side connecting portion 82 in the left-right direction increases as it approaches the main body portion 81 from the rear end portion 82a to the position P4, and except for the portion on the root side of the convex portion ( Fig. 27 The filler-body side connection part (excluding the part from P4 to P5 in the seat body) is formed into a columnar or truncated cone shape having a trapezoidal cross section extending in the vertical direction. The shape of the seat body side connection part 76 between the position P4 and the boundary position P5 is substantially the same as the shape of the filler-body side connection part 82 between the position P4 and the boundary position P5. Therefore, the left-right length L4 of the filler-body side connection part 82 at the position P4 is longer than the left-right length L3 of the seat body side connection part 76 at a position closer to the main body 81 than the position P4.

[0218] However, the one member and the other member which are wedge-fitted to each other are not limited to the reference Figure 24 to Figure 27 The illustrated example, and as described above, the members may have any shape that enables one member to be fitted to the other member and thereby geometrically cannot fall off the other member.

[0219] The hole portion is filled with the filling body 8 including this configuration by inserting the filling body side coupling portion 82 into the seat body side coupling portion 76 of the seat body 7 and inserting the main body 81 into the hole portion 74. As described above, the filling body side coupling portion 82 has flexibility, and the left-right length of the filling body side coupling portion 82 increases from the rear side end portion 82a to the position P4 as it approaches the main body 81. Therefore, during the filling operation, the rear side end portion 82a moves backward from the position P5 in the seat body side coupling portion 76, so that the filling body side coupling portion 82 can fill the seat body side coupling portion 76. The filling body side coupling portion 82 can move from top to bottom and be inserted into the seat body side coupling portion 76 to fill the seat body side coupling portion.

[0220] When the filling body side coupling portion 82 is inserted into the seat main body side coupling portion 76 and the position of the filling body side coupling portion 82 in the front-rear direction and the left-right direction is restricted, the main body portion 81 is correspondingly positioned in the hole portion 74. As a result, the filling body 8 can correctly and easily fill the seat main body 7. Therefore, the automobile seat pad 300 can be correctly and easily manufactured.

[0221] In addition, the filling body side connecting portion 82 is in the protruding direction ( Fig. 27 The front-rear direction in the example of FIG. 1 is a direction perpendicular to the protruding direction ( Fig. 27The length L1 in the left-right direction (in the example of FIG. 1 ) is longer than the length L2 of the seat body side connecting portion 76 in the direction orthogonal to the protruding direction at least at a position P2 closer to the main body 81 than the position P1, so that the filling body side connecting portion 82 can be prevented from falling off from the seat body side connecting portion 76. As a result, the filling body 8 can be prevented from moving in the front-rear direction or the left-right direction and falling off from the seat body 7, and the automobile seat pad 300 with high firmness can be manufactured.

[0222] In addition, in this example, Fig.24 and Fig.25 Similarly, the density of the portion including the porous structure 1 in the filler side connecting portion 82 (in this example, the filler side connecting portion 82 itself is a convex portion as a mechanical connecting means) is higher than the density of the main body 81. In this example, the detailed structure for setting the density of the convex portion higher than the density of the main body 81 is as follows: Fig.24 and Fig.25 Therefore, in this example, we can also obtain Fig.24 and Fig.25 The example has the same effect.

[0223] In reference Figure 24 to Figure 27 In the various examples described above, it has been described that the mechanical connection means in the seat body side connection part 76 is a recessed part formed in the seat body 7, and the mechanical connection means in the filling body side connection part 82 is a convex part formed from the main body part 81, and the recessed part and the convex part are formed in a shape that can be wedge-fitted with each other, but the mechanical connection means in the seat body side connection part 76 may be a convex part formed from the seat body 7, and the mechanical connection means in the filling body side connection part 82 may be a recessed part formed in the main body part 81, and the recessed part and the convex part may be formed in a shape that can be wedge-fitted with each other. In this case, the density of the outer edge part 821 facing the recessed part on the filling body 8 side may be higher than the density of the seat body 7.

[0224] Subsequently, a method of manufacturing the automobile seat pad 300 as the passenger seat cushion member according to the embodiment of the present disclosure will be described.

[0225] First, refer to Fig.28 A method for manufacturing a porous structure included in a car seat pad 300 as a passenger seat cushion member according to an embodiment of the present disclosure is described. As an example, Fig.28 Shown is a 3D printer Fig.18 The porous structure 1 included in the filler 8 shown in the figure is included in the automobile seat pad 300 as the passenger seat cushion member according to the embodiment of the present disclosure. Fig.24 and Fig.26 The porous structure 1 shown in FIG.

[0226] First, three-dimensional shape data (for example, three-dimensional CAD data) representing the three-dimensional shape of the porous structural body 1 is generated in advance by using a computer.

[0227] Subsequently, the three-dimensional shape data is converted into 3D forming data 500 by using a computer. When the forming unit 420 of the 3D printer 400 performs forming, the 3D forming data 500 is read by the controller 410 of the 3D printer 400, and the controller 410 causes the forming unit 420 to form the porous structure 1. The 3D forming data 500 includes, for example, sheet layer data representing the two-dimensional shape of each layer of the porous structure 1.

[0228] Subsequently, the porous structural body 1 is formed by a 3D printer 400. The 3D printer 400 may perform forming by using any forming scheme such as an optical forming scheme, a powder sintering lamination scheme, a hot melt lamination scheme (FDM scheme), or an inkjet scheme. Fig.28 Forming by hot melt lamination approach (FDM approach) is shown.

[0229] The 3D printer 400 includes a controller 410 made of, for example, a CPU, etc., a forming section 420 configured to perform forming under the control of the controller 410, a support table 430 on which a forming object to be formed (i.e., a buffer member 301) is placed, and a container 440 that contains the liquid resin LR, the support table 430, and the forming object. The forming section 420 includes a laser emitter 421, which is configured to emit an ultraviolet laser beam LL when an optical forming scheme is used as in this example. The container 440 is filled with the liquid resin LR. By irradiation with the ultraviolet laser beam LL emitted from the laser emitter 421, the liquid resin LR is cured into a flexible resin.

[0230] In the 3D printer 400 thus constructed, first, the controller 410 reads the 3D shaping data 500 and sequentially shapes each layer based on the three-dimensional shape included in the read 3D shaping data 500 while controlling the shaping part 420 to emit the ultraviolet laser beam LL.

[0231] Note that when the porous structure 1 is made of resin, the porous structure 1 as the molding object can be heated in an oven after the molding is completed by the 3D printer 400. In this case, the connection between the layers included in the porous structure 1 can be strengthened to reduce the anisotropy of the porous structure 1, and thus the buffer member characteristics of the porous structure 1 can be further improved.

[0232] When the porous structural body 1 is made of rubber, after the molding by the 3D printer 400 is completed, the porous structural body 1 as the molding object may be vulcanized.

[0233] When the porous structure 1 is formed in this manner, the filling body 8 is manufactured by forming the filling body side connecting portion 82 by attaching the filling body side hook and loop fastener 822 to the outside of the outer edge portion 821 formed by a part of the porous structure 1. Then, the filling body side connecting portion 82 including the porous structure 1 is connected to the seat body side connecting portion 76 of the seat body 7, thereby filling the seat body 7 with the filling body 8.

[0234] Note that the example in which the filler 8 and the seat body 7 are formed so that the filler 8 is inserted from top to bottom into the hole portion 74 with the first body portion 811 located at the lower side has been described above, but the present disclosure is not limited to this example. For example, the porous structure 1 and the seat body 7 may be formed so that the porous structure 1 is inserted into the seat body 7 from the lower side thereof.

[0235] In addition, the filler body side hook and loop fastener 822 may be further mounted to the seat body 7 in such a manner that the removable mounting surface faces the main body step surface BS. Fig.19 In this case, the seat body side connecting portion 76 including the seat body side hook and loop fastener is arranged on the body step surface BS of the seat body 7 so that the removable mounting surface of the seat body side hook and loop fastener faces the pad step surface PS of the filler body 8.

[0236] Therefore, the filler-side hook-and-loop fastener 822 mounted to the pad step surface PS of the filler 8 is engaged with the seat body-side connecting portion 76 including the seat body-side fastener. As a result, the filler 8 can more firmly fill the seat body 7. The filler-side hook-and-loop fastener 822 mounted to the pad step surface PS and the seat body-side fastener mounted to the body step surface BS can be engaged with each other and then easily separated from each other, so that the filling operation is easily performed again so that the filler 8 fills the correct position in the seat body 7.

[0237] Note that the passenger seat cushion member according to claim 7 can be manufactured by using the method for manufacturing the passenger seat cushion member according to claim 1. The filler body according to claim 9 can be manufactured by using the method for manufacturing the passenger seat cushion member according to claim 8.

[0238] Next, we will refer to Fig.29 and Fig.30 illustrate Figures 1 to 4 A modified example of the skeleton portion 2 in the example.

[0239] This modification example Figures 1 to 4 The examples are different only in the structure of the bone portion 2B of the skeleton portion 2 of the porous structure 1.

[0240] The porous structure 1 may or may not necessarily include the above-mentioned membrane 3 ( Figure 5 ).

[0241] Fig.29 and Fig.30 yes Figures 1 to 4 An explanatory diagram of a modified example of the skeleton portion 2 in the example of FIG. Fig.29 is a plan view showing a part of a modified example of the skeleton portion 2, and corresponds to Figure 2 . Fig.30 The bone portion 2B of this example is shown alone. Fig.30 (a) shows a natural state where no external force is applied to the bone part 2B, Fig.30 (b) shows a state where an external force is applied to the bone part 2B. Fig.29 and Fig.30 The central axis (skeleton line O) of the bone portion 2B is shown.

[0242] like Fig.29 and Fig.30 As shown in (a), each bone portion 2B of the skeleton portion 2 includes a bone constant portion 2B1 extending while maintaining a constant cross-sectional area and a pair of bone change portions 2B2 extending from the bone constant portion 2B1 to the corresponding joint portion 2J while the cross-sectional areas on both sides of the extension direction of the bone constant portion 2B1 gradually change. In this example, each bone change portion 2B2 extends from the bone constant portion 2B1 to the corresponding joint portion 2J while the cross-sectional area gradually increases. Note that the present disclosure is not limited to this example, but the same effect can be obtained even when only a portion of the bone portions 2B included in the skeleton portion 2 meets the above-mentioned structure. A portion or all of the bone portions 2B of each bone portion 2B included in the skeleton portion 2 may include a bone change portion 2B2 only at the end portion of the bone constant portion 2B1 located on one side, and the end portion of the bone constant portion 2B1 located on the other side may be directly connected to the corresponding joint portion 2J, in which case the same effect can also be obtained to varying degrees.

[0243] Here, the cross-sectional area of ​​each of the bone constant portion 2B1 and the bone variation portion 2B2 is the cross-sectional area of ​​each of the bone constant portion 2B1 and the bone variation portion 2B2 perpendicular to the skeleton line O.

[0244] In this example, since each bone portion 2B included in the porous structure 1 includes a bone constant portion 2B1 and a bone change portion 2B2, and the cross-sectional area of ​​the bone change portion 2B2 gradually increases as the position moves from the bone constant portion 2B1 toward the corresponding joint portion 2J, the bone portion 2B has a contraction shape that becomes thinner toward the bone constant portion 2B1 near the boundary between the bone constant portion 2B1 and the bone change portion 2B2. Therefore, when an external force is applied, the bone portion 2B is prone to buckling deformation in the middle portion between the contraction portion and the bone constant portion 2B1, and therefore, the porous structure 1 is prone to compression deformation. As a result, behaviors and characteristics equivalent to those of general polyurethane foams manufactured by a chemical reaction foaming process can be obtained. In addition, as a result, the surface of the porous structure 1 provides a softer touch. For example, when sitting, especially when starting to sit, a softer feeling is provided to the seated person. This soft feeling is generally widely appreciated and is appreciated by seat occupants on passenger seat cushioning members of luxury automobiles (e.g., seat occupants on the back seat of a driver's car).

[0245] As in this example, when at least a portion of the bone portion 2B includes the bone constant portion 2B1, the cross-sectional area A0 ( Fig.30 (a)) with respect to the cross-sectional area A1 ( Fig.30 The ratio A0 / A1 of (a)) preferably satisfies:

[0246] 0.15≤A0 / A1≤2.0

[0247] Therefore, the surface of the porous structure 1 can provide a touch of appropriate hardness that is neither too soft nor too hard, which is a characteristic of a passenger seat cushion member. For example, when sitting down, especially when starting to sit down, a feeling of appropriate hardness is provided to the seated person. The smaller the ratio A0 / A1, the softer the touch provided by the surface of the porous structure 1. When the ratio A0 / A1 is less than 0.15, the surface of the porous structure 1 may provide a touch that is too soft, which is not preferred as a characteristic of a passenger seat cushion member. The porous structure is difficult to manufacture using a 3D printer, and is therefore disadvantageous in terms of manufacturability. When the ratio A0 / A1 exceeds 2.0, the surface of the porous structure 1 may provide a touch that is too hard, which is not preferred as a characteristic of a passenger seat cushion member.

[0248] Note that the ratio A0 / A1 is more preferably 0.5 or more.

[0249] More specifically, in this example, each bone portion 2B includes a bone constant portion 2B1 and a pair of bone variation portions 2B2 continuous with both sides of the bone constant portion, each bone variation portion 2B2 extends from the bone constant portion 2B1 to the corresponding joint portion 2J with a gradually increasing cross-sectional area, and the ratio A0 / A1 is less than 1.0. Therefore, the surface of the porous structure 1 provides a relatively soft touch as a characteristic of the passenger seat cushioning member. This soft feeling is generally widely appreciated and is appreciated by passengers on the passenger seat cushioning member of luxury cars (for example, passengers on the back seat of a car with a driver).

[0250] Note that each bone portion 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, or only a portion of the bone portions 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, and in any case, the same effect may be obtained to varying degrees.

[0251] Note that, unlike this example, each bone change portion 2B2 can extend from the bone constant portion 2B1 to the joint portion 2J with a gradually decreasing cross-sectional area. In this case, the cross-sectional area of ​​the bone constant portion 2B1 is greater than the cross-sectional area of ​​the bone change portion 2B2 (thicker than the bone change portion). Therefore, when an external force is applied, the bone constant portion 2B1 is hardly deformed, on the contrary, the bone change portion 2B2 (especially the part on the side of the joint portion 2J) is relatively easy to bend, so the porous structure 1 is hardly subjected to compression deformation. Therefore, the surface of the porous structure 1 provides a harder touch and obtains a high hardness mechanical property. For example, when sitting, especially when starting to sit, the porous structure provides a harder feeling to the seated person. General polyurethane foam manufactured by the foaming process of chemical reaction is not easy to obtain such performance. With such a structure, users who prefer a harder feeling can be supported. For example, a seated person on the passenger seat cushioning member of a sports car that performs sudden acceleration and deceleration and lane changes will appreciate this hard feeling.

[0252] Then, when the bone variation portion 2B2 extends from the bone constant portion 2B1 to the joint portion 2J with a gradually decreasing cross-sectional area, the ratio A0 / A1 exceeds 1.0.

[0253] Note that each bone portion 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, or only a portion of the bone portions 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, and in any case, the same effect may be obtained to varying degrees.

[0254] Note that in the first embodiment, Figures 1 to 4In the example of , each bone portion 2B may include only the bone constant portion 2B1 without the bone variable portion 2B2. In this case, the cross-sectional area of ​​the bone portion 2 is constant over its entire length. When an external force is applied, the surface of the porous structure 1 provides a medium hardness touch. With such a configuration, users who prefer a medium hardness feel can be supported. This configuration can be preferably applied to a passenger seat cushioning member of any vehicle type such as a luxury car or a sports car.

[0255] In this case, the ratio A0 / A1 is 1.0.

[0256] Note that each bone portion 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, or only a portion of the bone portions 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, and in any case, the same effect may be obtained to varying degrees.

[0257] return Fig.29 and Fig.30 In the example of, in this example, the cross-sectional area of ​​the bone constant portion 2B1 of each bone portion 2B included in the skeleton portion 2 is smaller than the cross-sectional area of ​​the bone variation portion 2B2 and the corresponding connecting portion 2J. More specifically, the cross-sectional area of ​​the bone constant portion 2B1 is smaller than the cross-sectional area of ​​any portion of each of the bone variation portion 2B2 and the connecting portion 2J (except the boundary portion between the bone constant portion 2B1 and the bone variation portion 2B2). In other words, the bone constant portion 2B1 is the (thin) portion with the smallest cross-sectional area in the skeleton portion 2. Therefore, as described above, when an external force is applied, the bone constant portion 2B1 is easily deformed, and thus the porous structure 1 is easily compressively deformed. As a result, the surface of the porous structure 1 provides a softer touch.

[0258] Note that the cross-sectional area of ​​each joint portion 2J is the cross-sectional area of ​​a cross section perpendicular to the skeleton line O of the joint portion 2J.

[0259] Note that the present disclosure is not limited to this example, and only a part of the bone parts 2B included in the skeleton part 2 may satisfy the above-mentioned configuration, and in this case, the same effect can be obtained to varying degrees.

[0260] Likewise, in the present example, the width of the bone constant portion 2B1 of each bone portion 2B included in the skeleton portion 2 is smaller than the width of the bone variation portion 2B2 and the corresponding connecting portion 2J. More specifically, the width of the bone constant portion 2B1 is smaller than the width of any portion of each of the bone variation portion 2B2 and the connecting portion 2J (except for the boundary portion between the bone constant portion 2B1 and the bone variation portion 2B2). In other words, the bone constant portion 2B1 is the smallest (thin) portion in the skeleton portion 2. Therefore, when an external force is applied, the bone constant portion 2B1 is easily deformed, and thus the surface of the porous structure 1 provides a softer touch.

[0261] Note that the widths of the bone constant portion 2B1, the bone variation portion 2B2, and the joint portion 2J are respectively the maximum widths measured along the cross sections of the bone constant portion 2B1, the bone variation portion 2B2, and the joint portion 2J perpendicular to the skeleton line O. The skeleton line O of the joint portion 2J is the portion of the skeleton line O corresponding to the joint portion 2J. Fig.30 (a) shows the width W0 of the bone constant portion 2B1 and the width W1 of the bone variation portion 2B2 for reference.

[0262] Note that the present disclosure is not limited to this example, and only a part of the bone parts 2B included in the skeleton part 2 may satisfy the above-mentioned configuration, and in this case, the same effect can be obtained to varying degrees.

[0263] In each of the above examples, the width W0 ( Fig.30 (a)) is preferably 0.05 mm or more, more preferably 0.10 mm or more. When the width W0 is 0.05 mm or more, it can be formed at the resolution of a high-performance 3D printer, and when the width is 0.10 mm or more, it can be formed not only at the resolution of a high-performance 3D printer but also at the resolution of a general-purpose 3D printer.

[0264] On the other hand, in order to improve the accuracy of the outer edge (outer contour) shape of the porous structure 1, reduce the gap (interval) between the pores C, and have excellent characteristics as a buffer member, the width W0 ( Fig.30 The thickness of (a)) is preferably 0.05 mm or more and 2.0 mm or less.

[0265] Note that each bone portion 2B included in the skeleton portion 2 preferably satisfies the above-mentioned configuration, but only a portion of the bone portions 2B included in the skeleton portion 2 may satisfy the above-mentioned configuration, and in this case, the same effect can also be obtained to varying degrees.

[0266] like Fig.30 As shown, in this example, the bone change portion 2B2 of each bone portion 2B included in the skeleton portion 2 has one or more (3 in this example) inclined surfaces 2B23 as side surfaces, each inclined surface 2B23 is inclined relative to the extension direction of the bone change portion 2B2 (inclined by less than 90°), and the width W2 gradually increases from the bone constant portion 2B1 toward the joint portion 2J.

[0267] Therefore, when external force is applied, bone portion 2B is easily buckled and deformed at the contraction portion near the boundary between bone constant portion 2B1 and bone variation portion 2B2, and porous structural body 1 is easily compressively deformed. As a result, the surface of porous structural body 1 provides a softer touch.

[0268] Here, the extension direction of the bone change portion 2B2 is the extension direction of the central axis (skeleton line O) of the bone change portion 2B2. The width W2 of each inclined surface 2B23 of the bone change portion 2B2 is the width of the inclined surface 2B23 measured along a cross section perpendicular to the skeleton line O of the bone change portion 2B2.

[0269] Note that the present disclosure is not limited to this example, and each bone portion 2B included in the skeleton portion 2 may have only a part of the bone portion 2B satisfying the above-described configuration, in which case the same effect can also be obtained to varying degrees.

[0270] In this example, each bone portion 2B in the skeleton portion 2 is columnar, and the cross-sectional shape of the bone constant portion 2B1 and the bone variation portion 2B2 is an equilateral triangle.

[0271] Therefore, the porous structure 1 has a simple structure and can therefore be easily formed by a 3D printer. In addition, the mechanical properties of a general polyurethane foam manufactured by a chemical reaction foaming process can be easily reproduced. Therefore, the properties of the buffer member of the porous structure 1 can be improved. In addition, since each bone portion 2B has a columnar shape in this manner, the durability of the porous structure 1 can be improved compared to the case where the bone portion 2B is replaced with a film portion.

[0272] Note that the cross-sectional shapes of the bone constant portion 2B1 and the bone variation portion 2B2 are shapes at a cross section perpendicular to the central axis (skeleton line O) of the bone constant portion 2B1 and the bone variation portion 2B2, respectively.

[0273] Note that the present disclosure is not limited to this example, and each bone portion 2B included in the skeleton portion 2 may have only a part of the bone portion 2B satisfying the above-described configuration, in which case the same effect can also be obtained to varying degrees.

[0274] In all or part of the bone portions 2B included in the skeleton portion 2, the cross-sectional shapes of the bone constant portion 2B1 and the bone variation portion 2B2 may be polygons other than equilateral triangles (such as triangles other than equilateral triangles, or rectangles), or may be circles (such as perfect circles or ellipses), in which case the same effect as that of the present example may be obtained. The cross-sectional shapes of the bone constant portion 2B1 and the bone variation portion 2B2 may be different from each other. Alternatively, the cross-sectional shapes of the bone portions 2B may be uniform along the extension direction, or may be non-uniform along the extension direction. Alternatively, the cross-sectional shapes of the bone portions 2B may be different from each other.

[0275] Description of Reference Numerals

[0276] 1Porous structure

[0277] 11. First porous structure

[0278] 12 Second porous structure

[0279] 2. Skeleton

[0280] 2B Bone

[0281] 2Be end of bone

[0282] 2B1 bone constant

[0283] 2B2 Bone Change Department

[0284] 2B21 End of the bone change portion on the joint side

[0285] 2B22 End of the bone changing part on the bone constant part side

[0286] 2B23 Inclined surface of bone change

[0287] 2J joint

[0288] 3. Film

[0289] 21 Bubble Division

[0290] 211 annular part

[0291] 211L Large ring

[0292] 211S small ring

[0293] 2111 Inner peripheral edge of annular portion

[0294] 300 Car seat cushion (passenger seat cushion component)

[0295] 310 cushion

[0296] 311 main pad

[0297] 312 side pads

[0298] 320 back cushion

[0299] 321 main pad

[0300] 322 side pads

[0301] 340 Headrest

[0302] 400 3D printers

[0303] 410 Controller

[0304] 420 Forming Department

[0305] 421 Main component nozzle

[0306] 430 support table

[0307] 440 Containment

[0308] LL UV laser beam

[0309] LR liquid resin

[0310] 500 3D forming data

[0311] 6 Epidermis

[0312] 6A Smooth part

[0313] 6B through hole

[0314] 6C column

[0315] 7-seat main body

[0316] 71 Lower buttocks

[0317] 72 Leg lower periphery

[0318] 73 slot

[0319] 74 hole

[0320] 721 Lower leg lower periphery

[0321] 721L Left side of the lower leg lower periphery

[0322] 721R Right side of the lower leg lower edge

[0323] 722 Upper leg lower periphery

[0324] 722L Left side of the lower periphery of the upper leg

[0325] 722R Right side of the lower edge of the upper leg

[0326] 723 Lower periphery of front leg

[0327] 723T upper end of the lower peripheral edge of the front leg

[0328] 75 backrest cushion connection part

[0329] 76 seat main body side connection

[0330] 761 Lower side seat body side connection part

[0331] 762 Upper side seat body side connection part

[0332] 8 Filling body

[0333] 81 Main body

[0334] 811 first main body

[0335] 812 Second main body

[0336] 82 Filling body side connection part

[0337] 821 outer edge

[0338] 8211 First outer edge

[0339] 8212 Second outer edge

[0340] 822 Filler body side hook and loop fastener (mechanical fastening means)

[0341] 8221 Filling body side first hook and loop fastener

[0342] 8222 Filling body side second hook and loop fastener

[0343] 82a Back side end

[0344] C bubble hole

[0345] O Skeleton Line

[0346] V1 imaginary surface

[0347] V1L large imaginary surface

[0348] V1S small imaginary surface

[0349] BS main body step surface

[0350] PS pad step surface

Claims

1. A method for manufacturing a passenger seat cushion member, the method comprising: manufacturing a passenger seat cushion member comprising a seat body and a filling body for filling a hole formed in the seat body; The seat body includes a seat body side connection portion, and the seat body side connection portion includes a mechanical connection means connected to the filling body, The filling body includes a main body, the main body includes a porous structure and a filling body side connecting part, the porous structure is made of flexible resin or rubber, the filling body side connecting part is arranged adjacent to the main body and includes a mechanical connecting means connected to the seat body side connecting part, at least a part of the filling body side connecting part includes the porous structure, The density of the portion including the porous structure in the filling body side connecting portion is higher than the density of the main body portion, The manufacturing method comprises: The step of forming the porous structure by using a 3D printer; and a step of connecting the filling body side connecting portion including the formed porous structure to the seat body side connecting portion to fill the seat body with the filling body, The porous structure comprises a skeleton part, The skeleton part comprises: Multiple bones, and a plurality of coupling parts, which respectively couple the ends of the plurality of bone parts to each other, The average cross-sectional area of ​​the bone portion in the portion including the porous structure in the filling-body-side coupling part is larger than the average cross-sectional area of ​​the bone portion in the main body part.

2. The method for manufacturing a passenger seat cushion member according to claim 1, characterized in that: The mechanical connection means in the seat body side connection part is a hook and loop fastener arranged on the outer surface of the seat body, and The mechanical fastening means in the filling body-side fastening portion is a hook and loop fastener arranged on the outside of the main body portion.

3. The method for manufacturing a passenger seat cushion member according to claim 1, characterized in that: The mechanical connection means in the seat body side connection part is a recessed part formed in the seat body, The mechanical connection means in the filling body side connection part is formed as a convex part protruding from the main body part, and The concave portion and the convex portion are formed in shapes capable of being wedge-fitted with each other.

4. The method for manufacturing a passenger seat cushion member according to any one of claims 1 to 3, characterized in that: The porous structure includes a skeleton portion defining a plurality of pores, and The skin portion is formed on at least a portion of the outer side of the frame portion and is integrated with the frame portion to block at least a portion of the plurality of pores, and at least a portion of the outer side of the skin portion is a surface.

5. The method for manufacturing a passenger seat cushion member according to claim 4, characterized in that: At least a portion of the surface of the skin portion is a curved surface.

6. The method for manufacturing a passenger seat cushion member according to claim 4 or 5, characterized in that: The porous structure includes a first porous structure and a second porous structure integrated with the first porous structure, and When a seated person sits on the passenger seat cushioning member, the second porous structural body protrudes beyond the first porous structural body in a direction intersecting a seating direction.

7. A passenger seat cushion member, comprising a seat body and a filling body for filling a hole formed in the seat body, characterized in that: The seat body includes a seat body side connection portion, and the seat body side connection portion includes a mechanical connection means connected to the filling body, The filling body comprises a main body and a filling body side connecting part, the main body comprising a porous structure made of flexible resin or rubber, the filling body side connecting part is arranged adjacent to the main body and comprises a mechanical connecting means connected to the seat main body side connecting part, at least a part of the filling body side connecting part comprises the porous structure, The density of a portion of the filling body side connecting portion including the porous structure is higher than the density of the main body portion, the filling body side connecting portion is connected to the seat main body side connecting portion, and By forming the porous structure using a 3D printer, The porous structure comprises a skeleton part, The skeleton part comprises: Multiple bones, and a plurality of coupling parts, which respectively couple the ends of the plurality of bone parts to each other, The average cross-sectional area of ​​the bone portion in the portion including the porous structure in the filling body-side connecting part is larger than the average cross-sectional area of ​​the bone portion in the main body part.

8. The passenger seat cushioning member according to claim 7, characterized in that: The bone portion has a circular or polygonal cross-sectional shape.

9. The passenger seat cushioning member according to claim 7 or 8, characterized in that: The porous structure comprises a skeleton part, The skeleton part comprises: Multiple bones, and a plurality of coupling parts, which respectively couple the ends of the plurality of bone parts to each other, and Each of the bone parts includes, in at least a portion of the bone part, a bone constant portion extending while maintaining a constant cross-sectional area, and The ratio A0 / A1 of the cross-sectional area A0 of the bone constant portion to the cross-sectional area A1 of the end on either side of the bone portion satisfies: 0.15≤A0 / A1≤2.

0.

10. A method for manufacturing a filling body, the filling body filling a hole portion formed in a seat body in a passenger seat cushioning member including a seat body and the filling body, The filling body includes a main body portion and a filling body side connecting portion, the main body portion includes a porous structure made of flexible resin or rubber, the filling body side connecting portion is arranged adjacent to the main body portion and includes a mechanical connecting means connected to the seat body, at least a part of the filling body side connecting portion includes the porous structure, The density of the portion including the porous structure in the filling body side connecting portion is higher than the density of the main body portion. The manufacturing method comprises: By forming the porous structure using a 3D printer, The porous structure comprises a skeleton part, The skeleton part comprises: Multiple bones, and a plurality of coupling parts, which respectively couple the ends of the plurality of bone parts to each other, The average cross-sectional area of ​​the bone portion in the portion including the porous structure in the filling body-side connecting part is larger than the average cross-sectional area of ​​the bone portion in the main body part.

11. A filling body for filling a hole formed in a seat body of a passenger seat cushion member, the passenger seat cushion member comprising the seat body and the filling body, characterized in that: The filling body includes a main body portion and a filling body side connecting portion, the main body portion includes a porous structure made of flexible resin or rubber, the filling body side connecting portion is arranged adjacent to the main body portion and includes a mechanical connecting means connected to the seat body, at least a part of the filling body side connecting portion includes the porous structure, The density of the portion including the porous structure in the filling body side connecting portion is higher than the density of the main body portion, and By forming the porous structure using a 3D printer, The porous structure comprises a skeleton part, The skeleton part comprises: Multiple bones, and a plurality of coupling parts, which respectively couple the ends of the plurality of bone parts to each other, The average cross-sectional area of ​​the bone portion in the portion including the porous structure in the filling body-side connecting part is larger than the average cross-sectional area of ​​the bone portion in the main body part.

Images