Seat cushion and forming die of seat cushion

Abstract

The invention provides a seat cushion capable of suppressing leakage of foaming materials and properly integrally forming a flow path cover, an air duct and a cushion main body, and a forming mold of the seat cushion. A seat cushion is provided with: a cushion main body provided with a concave ventilation path (14); a planar air duct (30) that constitutes the inner peripheral wall of the air passage; and a planar flow path cover (20) that covers the ventilation path. The air duct and the flow path cover are pre-molded into a predetermined shape and are integrally foam-molded with the pad main body. The flow path cover is arranged on the back side molding surface (5a) in an overlapping manner, and the peripheral edge part (23) of the flow path cover is provided with a cover bending part (24), and the cover bending part bends towards the seat surface side in a manner of forming a recess capable of receiving a bank part (5b) protruding from the back side molding surface. The air duct has a seat surface portion (34) extending along a region deviating from the air passage. The seat surface part abuts against the protruding top end of the cover bending part in a manner of forming a first gap (S1) for the foaming raw material to flow in relative to the flow path cover.

Description

Technical Field

[0001] This invention relates to a seat cushion and a molding die for the seat cushion. More specifically, it relates to a seat cushion having a ventilation channel formed on the back of the cushion and a flow channel cover that covers the ventilation channel from the seat back side, and a molding die for the seat cushion. Background Technology

[0002] Patent Document 1 discloses a seat back with a concave ventilation channel extending along the back of the cushion. The seat back has: an air duct integrally formed with the cushion body to constitute the inner peripheral wall of the ventilation channel; and a planar flow channel cover that covers the ventilation channel from the seat back side. The flow channel cover covers the air duct integrally formed with the cushion body from the seat back side. The flow channel cover is held in a state of covering the ventilation channel by being bonded to the air duct using an adhesive.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2013-100000 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] As described in the aforementioned literature, when the flow channel cover is subsequently assembled onto the molded cushion body, the flow channel cover may shift relative to its alignment with the air duct. In this case, the ventilation performance of the cushion may deteriorate. Therefore, for example, it is considered to integrally mold the flow channel cover and the air duct with the cushion body. However, poor molding may occur due to leakage of foaming material from the gap between the periphery of the flow channel cover and the molding surface, and from the gap between the flow channel cover and the air duct. Therefore, a cushion and a molding die for the cushion are provided that can properly integrally mold the flow channel cover and the air duct with the cushion body while suppressing the leakage of foaming material.

[0008] Methods for solving problems

[0009] To address the aforementioned issues, the present invention provides a seat cushion and a seat cushion molding die using the following methods.

[0010] The first invention is a seat cushion comprising: a cushion body having a concave ventilation channel extending along the back of the cushion; a planar air duct disposed along the back of the cushion in such a way as to form the inner peripheral wall of the ventilation channel; and a planar flow channel cover covering the ventilation channel from the seat back side, wherein the air duct and the flow channel cover are pre-formed into a predetermined shape to form a structure integrally foamed with the cushion body, the flow channel cover being disposed overlappingly on the molding surface of the molding die of the cushion body, and having a cover bend at the periphery of the flow channel cover, the cover bends toward the seat surface in such a way as to form a recess capable of accepting a dam protruding from the molding surface, the air duct having a seat surface extending along the back of the cushion in a region offset from the ventilation channel, the seat surface abutting against the protruding top end of the cover bend relative to the flow channel cover disposed on the molding surface in such a way as to form a gap for the foaming material of the cushion body to flow in.

[0011] According to the above structure, the flow path cover and air duct are appropriately integrated with the pad body through the inflow of foam material into the gap between them. This prevents the flow path cover from shifting relative to the air duct. Furthermore, the contact between the curved portion of the cover and the seat surface prevents foam material from crossing the curved portion and intruding between the flow path cover and the air duct. Additionally, the recess on the seat back side of the curved portion of the cover is positioned towards the molding surface, and the embankment of the molding surface enters the recess of the curved portion. Therefore, even if foam material leaks into the gap between the flow path cover and the molding surface, the embankment can intercept the leaked foam material. This prevents foam material from crossing the embankment and intruding between the flow path cover and the molding surface. As a result, molding defects caused by foam material leakage can be appropriately suppressed.

[0012] The second invention is a seat cushion. In the first invention described above, the seat surface has an air duct bend at its inner side in the inward direction compared to the cover bend, and this air duct bend bends protruding toward the seat back in a manner that abuts against the flow path cover. According to this structure, the air duct bend of the seat surface abuts against the flow path cover at its inner side in the inward direction compared to the cover bend. Therefore, even if the foaming material intrudes into the inner side by crossing the abutment between the cover bend and the seat surface, further intrusion of the foaming material into the inner side can be suppressed by the abutment between the air duct bend and the flow path cover. Furthermore, the air duct bend protrudes in a staggered manner with the cover bend. Therefore, the upright shape of the air duct bend intercepts the foaming material. As a result, intrusion of the foaming material into the ventilation path can be further suppressed.

[0013] According to a third invention of the present invention, in the first or second invention described above, the curved portion of the cover extends in a ring shape over the entire periphery of the flow path cover. Based on this structure, leakage of foaming material between the flow path cover and the air duct, and between the flow path cover and the molding die, can be suppressed throughout the entire periphery of the flow path cover.

[0014] According to a fourth invention of the present invention, in the first or second invention described above, the flow path cover has a support portion that protrudes into the ventilation duct from the seat back side and abuts against the bottom of the bottom surface of the air duct constituting the ventilation duct. According to this structure, the support portion can suppress deformation of the air duct caused by foaming pressure. Therefore, it is possible to prevent the abutment between the curved portion of the cover and the seat surface from being disrupted during foaming molding. As a result, the intrusion of foaming material into the ventilation duct can be more appropriately suppressed.

[0015] The fifth invention is a molding die for molding the seat cushion of the first or second invention described above. The molding die has an engaging portion protruding from the embankment and passing through through holes formed at the top of the curved cap portion and in the seat surface portion. This engaging portion presses the base end of the curved cap portion against the molding surface to engage with the seat surface portion, overcoming the elastic force of the curved cap portion. According to this structure, the engaging portion strongly presses the seat surface portion against the curved cap portion, and the curved cap portion against the molding surface. This allows for more effective suppression of leakage of the foaming material.

[0016] The sixth invention is a molding die for molding the seat cushion of the first or second invention described above, wherein the embankment is provided spaced apart from the curved portion of the cover in an initial state in which the embankment does not interfere with the curved portion of the cover. In the case of a structure where the embankment interferes with the curved portion of the cover in the initial state, due to installation deviation, the embankment pushes the curved portion upward, and the cover of the cover may float from the molding surface. However, according to the structure of the sixth invention, the embankment does not interfere with the curved portion of the cover, and the cover of the cover can be set to a state that appropriately overlaps with the molding surface. Therefore, leakage of foaming material between the cover of the cover and the molding die can be more appropriately suppressed. Attached Figure Description

[0017] Figure 1 This is a perspective view of the seat cushion according to the first embodiment.

[0018] Figure 2 This is a 3D view of the seat cushion from below.

[0019] Figure 3 This is a three-dimensional view showing the flow path cover disassembled from the gasket.

[0020] Figure 4 This is a three-dimensional diagram showing the air duct after disassembling the gasket.

[0021] Figure 5 This is a three-dimensional view of the flow path cover and air duct from the rear.

[0022] Figure 6 yes Figure 5 Enlarged view of section VI.

[0023] Figure 7 This is a top view of the seat cushion.

[0024] Figure 8 yes Figure 7 Sectional view along line VIII-VIII.

[0025] Figure 9 yes Figure 7 A sectional view along the IX-IX line.

[0026] Figure 10 Is with Figure 8 A schematic diagram of the molding die corresponding to the cross-section.

[0027] Figure 11 Is with Figure 9 A schematic diagram of the forming mold corresponding to the cross-section.

[0028] Figure 12 yes Figure 10 Enlarged view of part XII.

[0029] Figure 13 yes Figure 11 Enlarged view of Part XIII.

[0030] Figure 14 This is a deformed example of a hole forming a protrusion. Figure 12 The image corresponding to the enlarged view.

[0031] Explanation of reference numerals in the attached figures

[0032] 1 Seat Cushion

[0033] 2. Padding (seat cushion)

[0034] 2a Main roof slab

[0035] 2b side top plate

[0036] 3 seat cushions

[0037] 10 pads main body

[0038] 11 vents

[0039] 12 pad surface

[0040] 13 pad back

[0041] 14 ventilation channels

[0042] 15 pull-in slot

[0043] 20 flow cover

[0044] 21 opening holes

[0045] 22. Cover side support (support part)

[0046] 23 Peripheral

[0047] 24. Cover bend

[0048] 25. Through hole (through hole)

[0049] 26 First Arrival Section

[0050] 30 air duct

[0051] 31 bottom

[0052] 32 side wall portion

[0053] 33 partition section

[0054] 34 facial

[0055] 35 Air duct bend

[0056] 36 slits

[0057] 37. Through hole in the air duct (through hole)

[0058] 38 Second Arrival Section

[0059] 4 Molding molds

[0060] 4a chamber

[0061] 5. Upper mold 5a Back side forming surface (forming surface)

[0062] 5b Embankment

[0063] 5c mold side support

[0064] 5d interval

[0065] 6 lower molds

[0066] 6a Surface side molding surface

[0067] 6b hole forms a protrusion

[0068] 6c top

[0069] 6d base section

[0070] 6e bolts

[0071] 6f groove forms a protrusion

[0072] 7. Positioning pins (locking parts)

[0073] 7a shaft section

[0074] 7b Anti-hair loss section

[0075] 8b hole forms a protrusion

[0076] 8c top

[0077] 8d base section

[0078] 8e bolt

[0079] S1 First Gap (Gap)

[0080] S2 second gap. Detailed Implementation

[0081] The following uses Figure 1-14 The following description explains the method for implementing the present invention. In the following description, when referring to directions such as front, back, up, down, left, and right, it refers to the directions shown in each figure. In addition, when referred to as "seat width direction", it refers to the left and right direction of the seat cushion 1 described later.

[0082] <First Implementation Method>

[0083] First, the seat cushion of the first embodiment of the present invention will be described. Figure 1 As shown, the seat cushion is a pad 2 that constitutes the cushioning material of the seat cushion 1. The seat cushion 1 constitutes the seating part of a car seat. The seat cushion 1 has a plurality of ventilation holes 11 that penetrate the interior of the pad 2 in the thickness direction (vertical direction). Each ventilation hole 11 allows the interior of the pad 2 to be easily ventilated.

[0084] The seat cushion 1 has a blower (not shown) disposed below the liner 2. The blower is connected to the flow path of each vent 11, drawing in air from each vent 11 and exhausting it downwards from the seat cushion 1. In this way, the seat cushion 1 has a seat air conditioning function that actively ventilates the interior of the liner 2. As a result, the comfort of the seat cushion 1 can be improved by actively removing heat from the liner 2.

[0085] like Figure 2 , Figure 3 As shown, the cushion 2 has a cushion body 10 that elastically supports the buttocks of the seated person and a concave ventilation passage 14 extending along the back surface 13 of the cushion body 10. The ventilation passage 14 opens toward the seat back. Each vent 11 opens from a point on the ventilation passage 14. In addition, the cushion 2 has a planar flow path cover 20 that covers the ventilation passage 14 from the seat back. The flow path cover 20 closes the opening of the ventilation passage 14 toward the seat back. The flow path cover 20 has an opening 21 that opens in a circular shape from the center of its rear portion. The opening 21 is connected to the aforementioned blower. Therefore, air drawn in from each vent 11 flows along the ventilation passage 14 and is exhausted toward the seat back through the opening 21.

[0086] like Figure 3 , Figure 4As shown, the cushion 2 has a planar air duct 30 formed along the back surface 13 of the cushion, which acts as the inner peripheral wall of the ventilation passage 14. The air duct 30 is a pre-stamped nonwoven fabric in a predetermined shape. The air duct 30 is relatively rigid compared to the cushion body 10. Therefore, the strength of the ventilation passage 14 can be increased by the air duct 30. Thus, when a seating load is applied to the cushion 2, the ventilation passage 14 can maintain its shape without being crushed. As a result, the flow of air in the ventilation passage 14 is not easily obstructed, and the deterioration of the seat air conditioning function can be suppressed.

[0087] The aforementioned pad body 10 is composed of a polyurethane foam molded body. For example... Figure 10 , Figure 11 As shown, the pad body 10 is formed by foaming the foaming material flowing into the cavity 4a of the molding die 4. The flow path cover 20 and the air duct 30 are disposed within the cavity 4a during the foaming process of the pad body 10. Therefore, the flow path cover 20 and the air duct 30 are integrated with the pad body 10 during the foaming process. This allows for easy placement of the flow path cover 20 and the air duct 30 within the pad body 10. Furthermore, the flow path cover 20 can be appropriately positioned to align with the air duct 30 and the pad body 10.

[0088] If the flow path cover 20 deviates from its aligned position with the air duct 30 and the pad body 10, the opening 21 of the flow path cover 20 will be misaligned relative to the ventilation path 14 and the blower. Consequently, the ventilation performance of the pad 2 may deteriorate. Therefore, by properly positioning the flow path cover 20 relative to the air duct 30 and the pad body 10, the ventilation performance of the pad 2 can be appropriately maintained.

[0089] like Figure 12 As shown, the flow path cover 20 has a cover bend 24 that curves outward from its periphery 23 toward the air duct 30. The protruding shape of the cover bend 24 forms a first gap S1 between the flow path cover 20 and the air duct 30. The foaming material of the pad body 10 actively flows into this first gap S1. Thus, the flow path cover 20 and the air duct 30 can be appropriately integrated with respect to the pad body 10.

[0090] Furthermore, the curved portion 24 of the cover has a first contact portion 26 at its protruding tip that abuts against the air duct 30. Therefore, it is possible to prevent the foaming material flowing into the first gap S1 from crossing the curved portion 24 and intruding into the inner side in the in-plane direction. As a result, it is possible to prevent the foaming material from leaking into the ventilation passage 14 between the flow path cover 20 and the air duct 30.

[0091] Furthermore, the curved portion 24 of the cover is provided such that the recess on its seat back side faces the back side molding surface 5a of the upper mold 5. This curved portion 24 is subjected to the foaming pressure of the foaming material during the foaming molding of the pad body 10. As a result, the base end of the curved portion 24 is forcefully pressed against the back side molding surface 5a. Therefore, it is possible to suppress the intrusion of foaming material between the flow path cover 20 and the back side molding surface 5a. As described above, leakage of foaming material between the flow path cover 20 and the air duct 30, and between the flow path cover 20 and the back side molding surface 5a, can be suppressed, thereby appropriately preventing molding defects.

[0092] <Seat Cushion 1>

[0093] The following is a detailed description of the structures of the aforementioned seat cushion 1 and molding die 4. For example... Figure 1 As shown, the seat cushion 1 has a cushion frame (not shown) forming its skeleton, a cushion 2 assembled from above relative to the cushion frame, and a cushion cover 3 covering the cushion 2 from above. The cushion cover 3 rolls under the cushion 2 and is secured to the cushion frame. Thus, the cushion 2 is integrally assembled with respect to the cushion frame. The blower is mounted on the cushion frame. The blower is connected to the opening 21 of the flow path cover 20 through the assembly of the cushion 2 to the cushion frame (see reference). Figure 2 ).

[0094] <Pad 2>

[0095] like Figure 7 As shown, the cushion 2 has a main top plate 2a supporting the buttocks of the seated person from below and a pair of side top plates 2b supporting the buttocks of the seated person from the left and right sides. Additionally, the cushion 2 has a plurality of pull-in grooves 15 extending along its surface 12. Each pull-in groove 15 has a pair of left and right pull-in grooves located between the main top plate 2a and each side top plate 2b, and a pair of front and rear pull-in grooves extending left and right along the main top plate 2a. The top plate portion of the seat cover 3 is pulled in and locked into each pull-in groove 15. Thus, the seat cover 3 is tensioned and installed in a state of tight contact with the cushion 2 (see reference). Figure 1 ).

[0096] <Wind Path 30>

[0097] like Figure 4 , Figure 5 As shown, the air duct 30 is a generally rectangular member arranged along the entire area of ​​the ventilation passage 14. The air duct 30 has: a bottom 31, forming the bottom surface of the ventilation passage 14; sidewalls 32, rising from the periphery of the bottom 31 to form the sides of the ventilation passage 14; and partitions 33, protruding from the bottom 31 to partially divide the ventilation passage 14. Through each partition 33, the ventilation passage 14 is formed into a groove extending in multiple directions.

[0098] like Figure 5 , Figure 8As shown, the air duct 30 has a seat surface 34 that extends outward in a flange-like manner from the end of the side wall portion 32 toward the outer side in the in-plane direction. The seat surface 34 is formed to extend along the area of ​​the back surface 13 that deviates from the ventilation passage 14. The seat surface 34 has an air duct bend 35 that curves toward the seat back side between itself and the side wall portion 32. The air duct bend 35 is formed to extend in a ring shape along the entire periphery of the air duct 30. The air duct bend 35 is formed to bend toward the seat back side into a U-shaped cross-section. In addition, the seat surface 34 has a plurality of air duct through holes 37 that penetrate the seat surface 34 in the thickness direction. The air duct through holes 37 are arranged at predetermined intervals from each other in a manner that they are arranged along the entire periphery of the air duct 30.

[0099] like Figure 5 , Figure 6 As shown, each vent 11 opens from various points on the bottom 31. The air duct 30 has slits 36 extending from the periphery of each vent 11 along the diameter direction at four locations around each vent 11. Figure 12 As shown, a hole-forming protrusion 6b for forming the vent hole 11 of the vent 30 provided in the molding die 4 is inserted into the vent hole 11. The slits 36 can absorb the installation deviation when inserting the hole-forming protrusion 6b. Thus, the hole-forming protrusion 6b can be properly inserted into the vent hole 11.

[0100] <Flow Cover 20>

[0101] like Figure 3 , Figure 5 As shown, the flow channel cover 20 is a generally rectangular member extending along the shape of the air duct 30. The flow channel cover 20 is positioned to cover the entire area of ​​the air duct 30 from the seat back side. The flow channel cover 20 is a pre-stamped nonwoven fabric with a predetermined shape. The flow channel cover 20 has cover-side support portions 22 protruding toward the seat surface on both sides in the seat width direction at its rear. Additionally, the flow channel cover 20 has a cover bend 24 that curves toward the seat surface from its peripheral portion 23. The cover bend 24 is formed to extend in a ring shape along the entire periphery of the flow channel cover 20. The cover bend 24 is formed to protrude from a position that extends inward in the in-plane direction compared to the outer periphery of the flow channel cover 20.

[0102] Additionally, the flow path cover 20 has a plurality of cover through holes 25 extending through the cover bend 24 in the thickness direction. The cover through holes 25 are arranged at predetermined intervals from each other, arranged along the entire periphery of the flow path cover 20. For example... Figure 9 As shown, the cover bend 24 is curved towards the seat surface in a U-shaped cross-section. Each cover through hole 25 is formed as an opening from the protruding top end of the cover bend 24.

[0103] <Molding Die 4>

[0104] like Figure 10 , Figure 11 As shown, the molding die 4 has an upper metal die 5 and a lower die 6 facing each other vertically. The upper die 5 and the lower die 6 can be separated from each other; for example, the upper die 5 is configured to be movable in the vertical direction. The upper die 5 and the lower die 6 form a cavity 4a between their molding surfaces 5a and 6a by closing the mold. The cavity 4a forms the outer peripheral surface shape of the pad body 10. The flow path cover 20 is disposed on the upper die 5 from below in an overlapping manner. Furthermore, the air duct 30 is disposed on top of the flow path cover 20 from below in an overlapping manner.

[0105] <Upper mold 5>

[0106] The upper mold 5 has a back-side molding surface 5a formed on its lower surface. The back-side molding surface 5a forms the surface shape of the back surface 13 of the pad body 10. Additionally, as... Figure 11 As shown, the upper mold 5 has a mold-side support portion 5c that protrudes from the back side molding surface 5a in a trapezoidal cross-section. The mold-side support portion 5c passes through the opening 21 of the flow path cover 20 via the provision of the flow path cover 20. Furthermore, the mold-side support portion 5c abuts against the bottom 31 of the air duct 30 from above via the provision of the air duct 30. As a result, it is possible to prevent the air duct 30 from being crushed upwards by the foaming pressure of the foaming material. Consequently, it is possible to prevent the ventilation path 14 from narrowing.

[0107] like Figure 12 As shown, the upper mold 5 has a dam 5b protruding from the back side molding surface 5a. The dam 5b enters the recess of the cap bend 24 through the provision of the flow path cover 20. The dam 5b is formed to enter the entire area extending in the direction of the cap bend 24. The dam 5b constitutes a dam that intercepts the foaming material when it leaks between the flow path cover 20 and the back side molding surface 5a. Thus, it is possible to prevent the foaming material from crossing the dam 5b and intruding into the inner side in the in-plane direction. Here, the back side molding surface 5a corresponds to the "molding surface" of the present invention.

[0108] The embankment 5b is positioned at a distance of 5d from the curved portion 24 of the cap. This prevents interference between the embankment 5b and the curved portion 24 when the flow path cap 20 is positioned on the back side molding surface 5a. This also prevents the embankment 5b from pressing against the curved portion 24 due to installation misalignment of the flow path cap 20, thus preventing the flow path cap 20 from floating off the back side molding surface 5a. In other words, the flow path cap 20 can be positioned to appropriately overlap with the back side molding surface 5a. Therefore, leakage of foaming material into the gap between the flow path cap 20 and the back side molding surface 5a can be appropriately suppressed.

[0109] like Figure 13As shown, the upper mold 5 has a plurality of locating pins 7 for holding the installed flow path cover 20 and air duct 30 on the back side molding surface 5a. Each locating pin 7 has a shaft portion 7a mounted in a manner that protrudes downward from the top end of the dike portion 5b and an anti-detachment portion 7b formed at the top end of the shaft portion 7a with a diameter larger than the shaft portion 7a. The shaft portion 7a is mounted, for example, by screwing into a threaded hole provided in the dike portion 5b. Each locating pin 7 is provided at a position corresponding to each cover through hole 25 of the flow path cover 20. Each cover through hole 25 passes through each locating pin 7 from below through the installation of the flow path cover 20. As a result, each cover through hole 25 hooks over the anti-detachment portion 7b of each locating pin 7 in the installation direction. By hooking, the flow path cover 20 is prevented from falling off relative to each locating pin 7. Thus, the flow path cover 20 is held in place and does not fall off.

[0110] Furthermore, each air duct through hole 37 of the seat surface 34 of the air duct 30 passes through each positioning pin 7 from below through the air duct 30. Thus, each air duct through hole 37 hooks over the anti-detachment portion 7b of each positioning pin 7 in the setting direction. The seat surface 34, locked to each positioning pin 7, is pressed relative to the cover bend 24. The cover bend 24 is clamped between the back side molding surface 5a and the seat surface 34, generating an elastic force. Overcoming this elastic force, each anti-detachment portion 7b presses the base end of the cover bend 24 forcefully against the back side molding surface 5a. This makes it difficult for a gap to form between the flow path cover 20 and the back side molding surface 5a. Here, the positioning pin 7 corresponds to the "engaging portion" of the present invention. Additionally, the cover through hole 25 and the air duct through hole 37 correspond to the "through hole" of the present invention.

[0111] <Lower Mold 6>

[0112] like Figure 10 , Figure 11 As shown, the lower mold 6 has a surface-side molding surface 6a formed on its upper surface. The surface-side molding surface 6a forms the surface shape of the pad surface 12 of the pad body 10. The lower mold 6 has a plurality of groove-forming protrusions 6f protruding from the surface-side molding surface 6a. Each groove-forming protrusion 6f forms the inner circumferential surface shape of each pull-in groove 15. In addition, the lower mold 6 has a plurality of hole-forming protrusions 6b protruding from the surface-side molding surface 6a. Figure 12 As shown, the hole forming protrusion 6b has a base portion 6d protruding from the surface side forming surface 6a, and a top portion 6c that can be detachably mounted on the top of the base portion 6d.

[0113] The top portion 6c is fixed to the base portion 6d by bolts 6e. The top portion 6c is a truncated cone shape extending into a tapering shape at the top. Each top portion 6c is inserted into the vent hole 11 of the air duct 30 from below by the mutual closing of the upper mold 5 and the lower mold 6. Each top portion 6c, due to its tapering shape at the top, fits tightly against the periphery of each vent hole 11 without creating gaps. As a result, leakage of foaming material from each vent hole 11 into the ventilation passage 14 can be suppressed.

[0114] Furthermore, each tip 6c abuts against the flow path cover 20 from below. This makes it easier to maintain the flow path cover 20 relative to the back side molding surface 5a, preventing misalignment. The tip 6c is designed to be detachable, allowing other tip 6c to be mounted on the base portion 6d for the hole forming protrusion 6b. For example, tip 6c with a larger or smaller tilt angle that tapers to the tip can be mounted, or tip 6c with different diameters can be mounted. This simplifies the handling of air ducts 30 with different orifice diameters in the vent holes 11.

[0115] As another implementation method, such as Figure 14 As shown, the lower mold 6 may also have a hole-forming protrusion 8b. The top end 8c of the hole-forming protrusion 8b is fixed to the base portion 8d by a plurality of bolts 8e inserted radially along the base portion 8d. Thus, by adjusting the tightness of each bolt 8e, the radial arrangement of the top end 8c can be adjusted. This further absorbs installation deviations of the air duct 30, ensuring that the top end 8c fits properly against each vent hole 11.

[0116] <Overlap of flow path cover 20 and air duct 30>

[0117] like Figure 12 As shown, a first gap S1 opening outwards is formed between the peripheral portion 23 and the seat portion 34 of the flow path cover 20 via the cover bend 24. The foaming material actively flows into this first gap S1 during the molding of the pad body 10. Therefore, the pad body 10 is formed to be integrated with both the peripheral portion 23 and the seat portion 34. This allows for proper integration of the flow path cover 20 and the air duct 30 relative to the pad body 10. Here, the first gap S1 corresponds to the "gap" of the present invention.

[0118] Furthermore, the curved portion 24 of the cover has a first contact portion 26 that abuts against the seat surface 34 of the air duct 30 through the arrangement of the air duct 30. The first contact portion 26 abuts against the seat surface 34 along the entire periphery of the flow path cover 20 in a line extending along the extension direction of the curved portion 24. The first contact portion 26 can prevent the foaming material flowing into the first gap S1 from passing over the curved portion 24 and leaking between the flow path cover 20 and the air duct 30.

[0119] Furthermore, the duct bend 35 of the seat surface 34 has a second abutting portion 38 that abuts against the flow path cover 20 through the arrangement of the duct 30. The second abutting portion 38 extends along the entire periphery of the duct 30 and abuts against the flow path cover 20 line. The second abutting portion 38 is formed on the inner side in the in-plane direction than the first abutting portion 26. A second gap S2 is formed between the first abutting portion 26 and the second abutting portion 38. The second gap S2 constitutes a space for retaining foaming material in the event that the foaming material leaks inward over the first abutting portion 26. In addition, the duct bend 35 is configured to protrude alternately with the cover bend 24. Therefore, the duct bend 35 forms a dam to intercept the foaming material flowing into the second gap S2. As a result, it is possible to more appropriately suppress the leakage of foaming material into the ventilation passage 14 over the second abutting portion 38.

[0120] In addition, such as Figure 13 As shown, the cover-side support portion 22 of the flow path cover 20 abuts against the bottom 31 of the air duct 30 from above through the arrangement of the air duct 30. This prevents the air duct 30 from being crushed upwards by the foaming pressure of the foaming material. Consequently, the narrowing of the ventilation passage 14 is prevented. Furthermore, by suppressing deformation of the air duct 30, the separation of the abutment portions 26 and 38 between the flow path cover 20 and the air duct 30 during molding is prevented. This further reduces leakage of the foaming material into the ventilation passage 14. Here, the cover-side support portion 22 corresponds to the "support portion" of the present invention.

[0121] <Manufacturing Method of Pad Body 10>

[0122] The following describes the manufacturing process of the pad body 10. Initially, the flow path cover 20 and the air duct 30 are pre-formed into a predetermined shape by stamping. Furthermore, the upper mold 5 and the lower mold 6 are not in a closed-fitting state. First, the flow path cover 20 is placed overlappingly on the back side forming surface 5a of the upper mold 5. (As follows...) Figure 13 As shown, the locating pin 7 passes through the cover through hole 25 of the cover bend 24. Additionally, the embankment 5b of the upper mold 5 enters the recess of the cover bend 24. Furthermore, as... Figure 11 As shown, the mold side support 5c of the upper mold 5 passes through the opening 21 of the flow path cover 20 (see reference). Figure 11 ).

[0123] Next, the air duct 30 is arranged in an overlapping manner relative to the set flow path cover 20. For example... Figure 13 As shown, the positioning pin 7 passes through the air duct through-hole 37 of the seat surface 34. Therefore, the top end of the air duct bend 35 is pressed against the flow path cover 20 (second abutment portion 38). Additionally, as... Figure 12As shown, the seat surface 34 abuts against the top end of the cover bend 24 (first abutment portion 26) in a pressed manner. Furthermore, the base end of the cover bend 24 is pressed against the back side molding surface 5a. A first gap S1 and a second gap S2 are formed between the flow path cover 20 and the air duct 30. Additionally, as... Figure 11 As shown, the cover-side support portion 22 of the flow path cover 20 and the mold-side support portion 5c of the upper mold 5 abut against the bottom 31 of the air duct 30 from above.

[0124] Next, as Figure 10 , Figure 11 As shown, the upper mold 5 and the lower mold 6 are joined together. This forms a cavity 4a for molding the pad body 10. Additionally, protrusions 6b formed by the holes in the lower mold 6 pass through the vent holes 11 of the air duct 30 and abut against the flow path cover 20. Then, foaming material is added into the cavity 4a, causing the pad body 10 to foam and mold. The pad surface 12 is formed through the surface-side molding surface 6a. The pad back surface 13 is formed through the back-side molding surface 5a. Vent holes 11 penetrating the pad body 10 are formed through the protrusions 6b formed by the holes. Pull-in grooves 15 are formed through the protrusions 6f formed by the grooves.

[0125] like Figure 12 , Figure 13 As shown, the foaming material flows into the first gap S1, and the peripheral portion 23 of the flow path cover 20 and the seat portion 34 of the air duct 30 are integrated with the pad body 10. Furthermore, the seat portion 34 is pressed against the flow path cover 20 by the foaming pressure. Therefore, the seat portion 34 is pressed more strongly against the first abutment portion 26. Additionally, the second abutment portion 38 is pressed more strongly against the flow path cover 20. This more effectively prevents the foaming material from intruding into the ventilation passage 14 between the flow path cover 20 and the air duct 30. Moreover, the base end of the cover bend 24 is pressed more strongly against the back side molding surface 5a. This more effectively prevents the foaming material from intruding between the flow path cover 20 and the back side molding surface 5a. Thus, leakage of the foaming material can be suppressed, and the flow path cover 20 and the air duct 30 can be appropriately integrally molded relative to the pad body 10.

[0126] In summary, the seat cushion and the molding die for the seat cushion according to the first embodiment have the following structure. Hereinafter, the symbols shown in parentheses correspond to the structures shown in the above embodiments.

[0127] That is, the seat cushion (2) has: a cushion body (10) having a concave ventilation passage (14) extending along the back surface (13) of the cushion; a planar air duct (30) provided along the back surface (13) of the cushion in such a way as to form the inner peripheral wall of the ventilation passage (14); and a planar flow channel cover (20) covering the air duct (30) from the seat back side and covering the ventilation passage (14). The air duct (30) and the flow channel cover (20) are pre-formed into a predetermined shape and become a structure integrally foamed with the cushion body (10). The flow channel cover (20) is disposed overlappingly on the molding surface (5a) of the molding mold (4) of the cushion body (10), and has a cover bend (24) at its peripheral edge (23), which bends toward the seat surface in such a way as to form a recess that can accept the embankment (5b) protruding from the molding surface (5a). The air duct (30) has a seat surface (34) extending along the back of the pad (13) from the area deviated from the ventilation path (14). The seat surface (34) abuts against the protruding top of the cover bend (24) relative to the flow path cover (20) provided on the molding surface (5a) in such a way as to form a gap (S1) for the foaming material of the pad body (10) to flow in.

[0128] According to the above structure, the flow path cover (20) and the air duct (30) are appropriately integrated with the pad body (10) through the inflow of foam material into the gap between them. This prevents the flow path cover (20) from shifting relative to the air duct (30). Furthermore, the contact between the cover bend (24) and the seat surface (34) prevents foam material from crossing the cover bend (24) and intruding between the flow path cover (20) and the air duct (30). Additionally, the recess on the seat back side of the cover bend (24) is provided facing the molding surface (5a), and the embankment (5b) of the molding surface (5a) enters the recess of the cover bend (24). Therefore, even if foam material leaks between the flow path cover (20) and the molding surface (5a), the embankment (5b) intercepts the leaked foam material. This prevents foam material from crossing the embankment (5b) and intruding into the inner side. As a result, molding defects caused by leakage of foam material can be appropriately suppressed.

[0129] Furthermore, the seat surface (34) has an air duct bend (35) that bends inward toward the seat back at the inner side of the bend in the inward direction of the cover bend (24), in a manner that abuts against the flow path cover (20). According to the above structure, the air duct bend (35) of the seat surface (34) abuts against the flow path cover (20) at the inner side of the bend in the inward direction of the cover bend (24). Thus, even if the foaming material intrudes into the inner side by crossing the abutment between the cover bend (24) and the seat surface (34), the abutment between the air duct bend (35) and the flow path cover (20) can suppress further intrusion of the foaming material into the inner side. Moreover, the air duct bend (35) protrudes in a manner that is offset from the cover bend (24). Therefore, the upright shape of the air duct bend (35) intercepts the foaming material. As a result, the intrusion of the foaming material into the ventilation passage (14) can be further suppressed.

[0130] In addition, the curved portion (24) extends in a ring shape along the entire periphery of the flow path cover (20). According to the above structure, leakage of foaming material into the flow path cover (20) and the air duct (30), and between the flow path cover (20) and the molding die (4) can be suppressed throughout the entire periphery of the flow path cover (20).

[0131] Furthermore, the flow path cover (20) has a support portion (22) that protrudes into the ventilation passage (14) from the seat back side and abuts against the bottom (31) of the bottom surface of the air duct (30) constituting the ventilation passage (14). According to this structure, the support portion (22) can suppress deformation of the air duct (30) caused by foaming pressure. This prevents disruption of the contact between the cover bend (24) and the seat surface (34). Consequently, the intrusion of foaming material into the ventilation passage (14) can be appropriately suppressed.

[0132] Furthermore, the molding die (4) has a locking part (7) that protrudes from the embankment (5b) and passes through the through holes (25, 37) formed at the top of the cap bend (24) and the seat surface (34), thereby locking the base end of the cap bend (24) against the molding surface (5a) by overcoming the elastic force of the cap bend (24). According to the above structure, the locking part (7) presses the seat surface (34) and the cap bend (24), as well as the cap bend (24) and the molding surface (5a) together forcefully. As a result, leakage of the foaming material can be more appropriately suppressed.

[0133] Furthermore, the embankment (5b) is positioned at a distance (5d) from the bend in the cover (24) so ​​that it does not interfere with the bend in the cover (24) in the initial state when the flow path cover (20) is installed. In the case where the embankment (5b) interferes with the bend in the cover (24) in the initial state, due to installation deviation, the embankment (5b) may lift the bend in the cover (24), and the flow path cover (20) may float off the molding surface (5a). However, according to the above structure, the embankment (5b) will not interfere with the bend in the cover (24), and the flow path cover (20) can be appropriately set to overlap with the molding surface (5a). As a result, leakage of foaming material between the flow path cover (20) and the molding die (4) can be more appropriately suppressed.

[0134] <Other Implementation Methods>

[0135] The present invention has been described above using one embodiment, but the present invention can be implemented in various other ways besides the above embodiment.

[0136] 1. In addition to seat cushions, seat cushions can also be used on seat backs. Besides car seats, seat cushions are widely used in seats on various other modes of transportation such as railways, airplanes, and ships.

[0137] 2. The bends in the cover and the duct may not extend throughout the entire perimeter; they may only be formed along a portion of the outer perimeter. The bends in the cover and the duct may also extend discontinuously.

[0138] 3. The molding die may also have a flow path cover and air duct in the lower die. The embankment may also be formed as a structure that fits tightly against the recess of the curved part of the cover without any gaps.

[0139] 4. Positioning pins can also be installed on the mold by passing through the through holes after the flow path cover and air duct have been set.

Claims

1. A seat cushion, wherein, have: The main body of the pad has a concave ventilation channel extending along the back of the pad; A planar air duct is provided along the back of the pad in such a way as to form the inner peripheral wall of the ventilation path; as well as A planar flow channel cover extends from the seat back side, covering the air duct and thus the ventilation path. The air duct and the flow path cover are pre-formed into a specified shape, forming a structure integrally foamed with the pad body. The flow path cover is disposed overlappingly on the molding surface of the molding die of the cushion body, and has a cover bend at the periphery of the flow path cover. The cover bend is bent toward the seat surface in a manner that allows for the formation of a recess that can accommodate a dam protruding from the molding surface. The air duct has a seat surface extending along the back of the pad from a region offset from the ventilation path, the seat surface abutting against the protruding tip of the curved portion of the flow path cover disposed on the molded surface in such a way as to form a gap for the foaming material of the pad body to flow in.

2. The seat cushion according to claim 1, wherein, The seat surface has an air duct bend on the inner side in the inward direction compared to the bend of the cover, which bends protruding toward the seat back in a manner that abuts against the air duct cover.

3. The seat cushion according to claim 1 or 2, wherein, The curved portion of the cover extends in a ring shape around the entire periphery of the flow path cover.

4. The seat cushion according to claim 1 or 2, wherein, The flow path cover has a support portion that protrudes into the ventilation path from the seat back side and abuts against the bottom of the bottom surface of the air duct that forms the ventilation path.

5. A molding die for molding the seat cushion according to claim 1 or 2, wherein, The molding die has a locking part that protrudes from the embankment and passes through through holes formed at the top of the curved part of the cover and the seat surface, thereby locking the base end of the curved part of the cover against the molding surface by overcoming the elastic force of the curved part of the cover.

6. A molding die for molding the seat cushion according to claim 1 or 2, wherein, The embankment is positioned at intervals relative to the bend of the cover in such a way that the embankment does not interfere with the bend of the cover in the initial state of the flow path cover being installed.

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