Armrest, method for manufacturing armrest, and mold

Abstract

To solve the problem that a conventional armrest easily generates voids around a holder fitting recess of a foam resin part.SOLUTION: There is provided an armrest where a holder fitting recess to which a cup holder is fit is formed in a foam resin part of the armrest, wherein a lateral groove extending in a width direction of the armrest is provided on an inner face on a base end side of the armrest in the holder fitting recess.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present disclosure relates to an armrest, a method for manufacturing the same, and a mold used for manufacturing the armrest.

Background Art

[0002] As a conventional armrest, there is known one in which a holder fitting recess for fitting a cup holder is formed in a foamed resin part (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the conventional armrest, there has been a problem that voids are likely to occur around the holder fitting recess of the foamed resin part.

Means for Solving the Problems

[0005] One aspect of the invention is an armrest in which a holder fitting recess for fitting a cup holder is formed in a foamed resin part of the armrest, and a horizontal groove extending in the width direction of the armrest is provided on the inner surface of the base end side of the armrest in the holder fitting recess.

Brief Description of the Drawings

[0006]

Figure 1

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Mode for Carrying Out the Invention

[0007] [First Embodiment] In Figure 1, the armrest 10 of this embodiment is shown. In the example of this embodiment, the armrest 10 is used for the rear seat of a vehicle. The armrest 10 can be rotated and changed between a use state that extends forward to receive the elbow of the occupant and a storage state that extends upward to form a part of the backrest

[0008] In the example of this embodiment, the armrest 10 has a flat shape with an elbow receiving surface 10A for receiving the elbows of the occupant and a backrest surface 10B for receiving the back of the occupant on the front and back sides, and the base end portion in the longitudinal direction of the armrest 10 is assembled to the vehicle body (in the example of this embodiment, the rear seat). Further, in the example of this embodiment, a cup holder 30 is provided at the tip side portion of the armrest 10, and the cup holder 30 opens to the elbow receiving surface 10A that faces upward in the use state of the armrest 10.

[0009] The armrest 10 includes a foamed resin portion 12. A holder fitting recess 12A is formed on the elbow receiving surface 10A side (front side) of the foamed resin portion 12. The cup holder 30 is received in the holder fitting recess 12A. In the example of this embodiment, the holder fitting recess 12A is formed so as to widen from the bottom side toward the opening. In the example of this embodiment, the holder fitting recess 12A is disposed at the tip side portion in the longitudinal direction of the armrest 10.

[0010] In the example of this embodiment, the armrest 10 includes a bag-shaped skin material 15 that covers the foamed resin portion 12 from the outside. An opening 15A (see FIG. 2) that overlaps with the holder fitting recess 12A is formed in the skin material 15. The cup holder 30 is inserted through the opening 15A of the skin material 15 and received in the holder fitting recess 12A of the foamed resin portion 12.

[0011] As shown in FIGS. 2 and 3, in the example of this embodiment, the armrest 10 includes a support frame 20 embedded in the foamed resin portion 12. The support frame 20 is rotatably assembled to the vehicle body (in the example of this embodiment, the rear seat).

[0012] In the example of this embodiment, the support frame 20 has the following structure. The support frame 20 is provided with a pair of opposing frames 21 that face each other in the width direction of the armrest 10 and extend in the longitudinal direction of the armrest 10. At the base ends of the pair of opposing frames 21 (the ends on the base end side of the armrest 10), a rotating shaft portion 23 that protrudes outside the foamed resin portion 12 is provided, and the rotating shaft portion 23 is assembled to the vehicle body as the rotating shaft of the armrest 10. As shown in FIG. 3, in the example of this embodiment, the support frame 20 is provided with a base end side connecting member 22 that extends in the width direction of the armrest 10 and connects the base ends of the pair of opposing frames 21 (for example, is fixed by overlapping from the front side between the base ends). The base end side connecting member 22 has a shaft shape and is arranged such that its end portion protrudes outside the foamed resin portion 12, and the protruding portion functions as a stopper that restricts the rotation range of the armrest 10 by contacting the vehicle body (for example, the rear seat).

[0013] In the example of this embodiment, the support frame 20 is also provided with a tip side connecting member 24 that connects the tip ends of the pair of opposing frames 21 and an intermediate connecting member 25 that connects the intermediate portions of the pair of opposing frames 21. For example, the tip side connecting member 24 is formed by bending a round bar into a substantially C shape, and is fixed to the pair of opposing frames 21 from the front side such that the cut of the C shape faces the base end side of the armrest 10. Inside the substantially C-shaped tip side connecting member 24, a cup holder 30 is received (that is, the cup holder 30 is arranged to be surrounded by the tip side connecting member 24), and the cup holder 30 is fixed to the tip side connecting member 24. For example, the support frame 20 is made of metal.

[0014] As shown in FIG. 2, in the example of this embodiment, the cup holder 30 is formed in a container shape with a flange portion 33 protruding outward from the opening edge. Inside the cup holder 30, a cup receiving portion 32 for receiving a cup (not shown) is provided.

[0015] In the example of this embodiment, engaging portions 35 project outward from a pair of opposing walls 34 that face each other in the longitudinal direction of the armrest 10 in the cup holder 30 (see FIGS. 2 and 4). The engaging portions 35 engage with the support frame 20 (specifically, the tip-side connecting member 24), and fix the cup holder 30 to the support frame 20. For example, a plurality (a pair in the example of this embodiment) of engaging portions 35 are provided for each opposing wall 34 in the width direction of the armrest 10.

[0016] As shown in FIG. 6, a horizontal groove 51 extending in the width direction of the armrest 10 is formed on the inner surface of the holder fitting recess 12A of the foamed resin portion 12 on the proximal end side of the armrest 10. The horizontal groove 51 is preferably disposed at a position closer to the bottom in the depth direction of the holder fitting recess 12A (the position closer to the bottom surface in the example shown in FIG. 6). In the example of this embodiment, the horizontal groove 51 is disposed at the bottom of the holder fitting recess 12A. Further, the horizontal groove 51 is disposed on the bottom side of the support frame 20 in the depth direction of the holder fitting recess 12A in the foamed resin portion 12. For example, the horizontal groove 51 may be provided over the entire width direction (the width direction of the armrest 10) of the holder fitting recess 12A, or may be provided only in a part of the width direction (for example, may be divided into a plurality).

[0017] In the example of this embodiment, vertical grooves 52 extending in the depth direction of the holder fitting recess 12A are formed on the inner surface of the holder fitting recess 12A of the foamed resin portion 12 (see FIG. 5). The vertical grooves 52 receive the engaging portions 35 of the cup holder 30. A plurality of vertical grooves 52 may be provided in the width direction of the armrest 10 according to the number of the engaging portions 35 (a pair is provided in the example of this embodiment). The horizontal groove 51 may be disposed so as to connect the vertical grooves 52, or may be disposed away from at least one or all of the vertical grooves 52.

[0018] Note that, as shown in FIG. 2, in the example of the armrest 10 of the present embodiment, a bezel 40 having an insertion port 40A through which the cup holder 30 is inserted is embedded in the foamed resin portion 12. The bezel 40 is formed, for example, in a rectangular frame shape in plan view with the insertion port 40A disposed inside. As shown in FIG. 2, in the example of the armrest 10 of the present embodiment, the bezel 40 is fixed to the tip-side connecting member 24 of the support frame 20, and the edge of the opening 15A of the skin material 15 is sandwiched between the flange portion 33 of the cup holder 30 and the bezel 40.

[0019] The armrest 10 of the present embodiment is manufactured, for example, as follows. FIGS. 7 and 8 show a mold 70 for molding the foamed resin portion 12 of the armrest 10. The mold 70 has a cavity 79 in which the foamed resin portion 12 is molded with the base end side of the armrest 10 on top and the tip side on the bottom. As shown in FIGS. 7 and 9, the mold 70 has a molding protrusion 78 for molding the holder fitting recess 12A of the foamed resin portion 12. For example, the molding protrusion 78 is formed such that the cross-sectional area decreases toward the protruding tip side, and in the example of the present embodiment, the upper surface (i.e., the surface facing the base end side of the armrest 10) is arranged to slope downward toward the protruding tip side.

[0020] A horizontal rib 77 for molding the horizontal groove 51 of the foamed resin portion 12 is formed on the molding protrusion 78. The horizontal rib 77 extends in the width direction of the armrest 10 and is disposed on the upper surface of the molding protrusion 78 (i.e., the surface facing the base end side of the armrest 10). The horizontal rib 77 is disposed at a position corresponding to the horizontal groove 51 of the foamed resin portion 12, and is disposed, for example, at a position closer to the protruding tip of the molding protrusion 78 (in the example of the present embodiment, at the protruding tip portion of the molding protrusion 78).

[0021] Note that, in the example of the present embodiment, a vertical rib for molding the vertical groove 52 of the foamed resin portion 12 is also provided on the upper surface of the molding protrusion 78. The horizontal rib 77 and the vertical rib are provided in numbers corresponding to the horizontal groove 51 and the vertical groove 52 of the foamed resin portion 12. When the horizontal groove 51 of the foamed resin portion 12 is configured to connect a pair of vertical grooves 52, the horizontal rib 77 is also arranged to connect a pair of vertical ribs.

[0022] As shown in FIG. 7, a support frame 20 is set in the mold 70. The support frame 20 is set so that the proximal end side of the support frame 20 is on the upper side, and is arranged so as to surround the molding protrusion 78 (in the example of the present embodiment, so as to be surrounded by the distal end side connecting member 24). At this time, in the example of the present embodiment, the support frame 20 is arranged on the proximal end side of the molding protrusion 78 rather than the horizontal rib 77. Specifically, as shown in FIG. 9, the support frame 20 is set inside the skin material 15, and then the bezel 40 is inserted into the skin material 15 from the opening 15A of the skin material 15, and the bezel 40 is fixed to the support frame 20 (specifically, the distal end side connecting member 24). In FIGS. 7, 8, 10, etc., the skin material 15, the bezel 40, etc. are omitted from the illustration.

[0023] Thereafter, the foaming raw material 71 is injected into the cavity 79 from above (see FIG. 7). At this time, in the example of the present embodiment, the foaming raw material 71 is supplied so as to be poured at least onto the upper surface of the molding protrusion 78 (the mold 70 is provided with a raw material injection port capable of injecting the foaming raw material 71 in this way). Then, the mold 70 is closed (see FIG. 8), and by foaming the foaming raw material 71 in the cavity 79, a foamed resin portion 12 is formed in the cavity 79 (in the example of the present embodiment, inside the skin material 15) (see FIG. 10), and the support frame 20 is embedded in the foamed resin portion 12.

[0024] Here, as shown in FIGS. 14 and 15, in the mold 70V for molding the foamed resin portion 12 of the conventional armrest, voids V may occur around the holder fitting recess 12A of the foamed resin portion 12 (particularly on the upper side which is the base end side of the armrest). In response to this, in order to investigate the cause, when the inventor of the present application conducted intensive studies, it was found that since the foaming raw material 71 rises while flowing around the molding protrusion 78 from the lower side while foaming, if there is a shortage of the foaming raw material 71 above the molding protrusion 78, a hypothesis was obtained that voids V are likely to occur above the molding protrusion 78. In particular, the molding protrusion 78 is provided such that the cross-sectional area becomes smaller toward the protruding tip side in order to facilitate demolding of the foamed resin portion 12, etc., and the upper surface of the molding protrusion 79 is arranged to slope downward toward the protruding tip side, so that the foaming raw material 71 is likely to flow down (see FIGS. 14 and 15). And based on this hypothesis, the finding was obtained that it is possible to suppress the generation of voids V by making it easier to retain the foaming raw material 71 on the upper surface of the molding protrusion 78.

[0025] In the manufacturing method of the armrest 10 of the present embodiment conceived based on the above finding, as shown in FIGS. 8 and 9, a mold 70 provided with a horizontal rib 77 on the molding protrusion 78 is used. Thereby, compared with the conventional mold 70V (see FIGS. 14 and 15) not provided with the horizontal rib 77, it becomes possible to retain the foaming raw material 71 on the upper surface of the molding protrusion 78 (see FIGS. 8 and 9). As a result, it becomes possible to suppress the generation of voids V around the holder fitting recess 12A in the foamed resin portion 12 (see FIG. 10).

[0026] The foaming raw material 71 is preferably poured into the base end side portion of the molding protrusion 78 rather than the horizontal rib 77 in the molding protrusion 78. By doing so, it becomes possible to make it easier to retain the foaming raw material 71 on the upper surface of the molding protrusion 78. Further, by providing ridges extending in the protruding direction of the molding protrusion 78, such as vertical ribs, on both sides or one side of the horizontal rib 77, it becomes possible to further suppress the foaming raw material 71 from flowing down from the upper surface of the molding protrusion 78. Such ridges may be connected to the horizontal rib 77, and in this case, it becomes possible to further suppress the foaming raw material 71 from flowing down from the upper surface of the molding protrusion 78.

[0027] As described above, when the foaming raw material 71 foams and hardens to form the foamed resin part 12, the foamed resin part 12 is taken out. Next, the cup holder 30 is inserted through the opening 15A of the skin material 15 and received in the holder fitting recess 12A, and the cup holder 30 (specifically, the engaging part 35) is fixed to the support frame 20 (specifically, the tip side connecting member 24) (see FIG. 5). At this time, the skin material 15 is sandwiched between the flange part 33 and the bezel 40 (see FIGS. 2 and 6). Thus, the armrest 10 is obtained.

[0028] [Other Embodiments] In the above embodiment, the lateral grooves 51 of the foamed resin part 12 may be provided at a plurality of positions in the depth direction of the fitting recess 12A. In this case, correspondingly, the lateral ribs 77 of the mold 70 may be provided at a plurality of positions in the protruding direction of the molding protrusion 78.

[0029] In the above embodiment, the armrest 10 is such that the cup holder 30 is fixed later to the foamed resin part 12 integrally formed with the skin material 15, but the armrest 10 may be such that the foamed resin part 12 is integrally formed with the skin material 15 and the cup holder 30. In this case, as shown in FIGS. 12 and 13, instead of providing the lateral ribs 77 on the molding protrusion 78, lateral ribs 77V may be provided on the surface of the cup holder 30 that faces upward (the proximal end side of the armrest 10) during foam molding. The lateral ribs 77V are preferably provided at a position near the bottom (for example, the bottom) in the depth direction of the cup holder 30 (the protruding direction of the molding protrusion 78). In this case, the above-mentioned protrusion extending in the protruding direction of the molding protrusion 78 may also be provided.

[0030] The armrest 10 may be configured such that the support frame 20 is embedded in the foamed resin part 12 formed by foam molding, and the skin material 15 and the cup holder are later covered.

[0031] The armrest 10 may be configured to be fixed in the use state and non-rotatable.

[0032] The armrest 10 is not limited to being used in vehicles and may be for vehicles other than cars. Further, the armrest 10 does not have to be for the rear seat and may be, for example, for the front seat. Also, the armrest 10 may be used for a seat provided outside of a vehicle (for example, a seat provided in a building). In the above-described embodiment, an example of the armrest 10 in which an insert part such as the support frame 20 is embedded in the foamed resin part was shown. However, the technology of the above-described embodiment can also be applied to an armrest without an insert part or a foamed resin molded product other than an armrest. Further, in the above-described embodiment, a cup holder was exemplified as the container-shaped member. However, the technology of the above-described embodiment can also be applied to a foamed resin molded product (for example, an armrest) in which a fitting recess for fitting a container-shaped member other than the cup holder is provided in the foamed resin part.

[0033] <Appendix> Hereinafter, the feature groups extracted from the above-described embodiment will be described while showing effects and the like as necessary. In the following feature groups, for ease of understanding, the corresponding configurations in the above-described embodiment are appropriately shown in parentheses or the like. However, these feature groups are not limited to the specific configurations shown in such parentheses or the like.

[0034] For example, the following feature groups of the present disclosure relate to "an armrest (foamed resin molded product), its manufacturing method, and a mold used for manufacturing the armrest (foamed resin molded product)". Regarding the background art of "as a conventional armrest (foamed resin molded product), one in which a holder fitting recess (a fitting recess into which a container-shaped member is fitted) for fitting a cup holder is formed in a foamed resin part is known (for example, see JP-A-2006-95895 (FIGS. 3, 13, etc.).)", it can be considered that these feature groups were conceived with the problem of "in a conventional armrest (foamed resin molded product), voids are likely to occur around the holder fitting recess (the fitting recess of the foamed resin part) of the foamed resin part." Further, conventionally, new technologies related to an armrest (foamed resin molded product), its manufacturing method, and a mold used for manufacturing the foamed resin part have been provided.

[0035] [Feature 1] An armrest in which a holder fitting recess into which a cup holder is fitted is formed in a foamed resin portion of the armrest, The armrest includes a horizontal groove extending in the width direction of the armrest on an inner surface of the holder fitting recess on the proximal end side of the armrest.

[0036] [Feature 2] The armrest according to Feature 1, wherein the horizontal groove is disposed at a position closer to the bottom surface in the depth direction of the holder fitting recess.

[0037] [Feature 3] The armrest according to Feature 1, further comprising a support frame embedded in the foamed resin portion and attached to a vehicle, wherein the horizontal groove is provided on a bottom surface side in the depth direction of the holder fitting recess rather than the support frame.

[0038] [Feature 4] The armrest according to Feature 1, wherein a pair of vertical grooves extending in the depth direction of the holder fitting recess are formed on the inner surface of the holder fitting recess, and the horizontal groove connects between the pair of vertical grooves.

[0039] [Feature 5] A method for manufacturing an armrest in which a holder fitting recess into which a cup holder is fitted is formed in a foamed resin portion of the armrest, A mold having a cavity in which the foamed resin portion is molded with the proximal end side of the armrest upward and the distal end side downward is prepared, A horizontal rib extending in the width direction of the armrest is provided on an upper surface of a forming protrusion that forms the holder fitting recess in the mold, The method for manufacturing an armrest, wherein a foamed resin raw material is injected from above onto the upper surface of the forming protrusion to form the foamed resin portion.

[0040] [Feature 6] A mold for molding the foamed resin portion of an armrest in which a holder fitting recess into which a cup holder is fitted is formed in a foamed resin portion of the armrest, A cavity in which the foamed resin part is molded in a posture where the proximal end side of the armrest is upward and the distal end side is downward, A horizontal rib formed on the upper surface of a molding protrusion that molds the holder fitting recess in the mold and extending in the width direction of the armrest, A mold comprising a raw material injection port capable of injecting a foaming raw material from above onto the upper surface of the molding protrusion.

[0041] [Feature 7] A foamed molded article in which a fitting recess (holder fitting recess 12A) into which a container-like member (cup holder 30) is fitted is molded in the foamed resin part, A foamed resin molded article having a horizontal groove extending in the width direction of the container-like member (a direction intersecting the direction in which the foaming raw material is injected) on the inner surface of the fitting recess on the side where the foaming raw material is injected in the foamed resin molded article.

[0042] According to each of the above features, it is possible to suppress the generation of voids around the holder fitting recess (the fitting recess into which the container-like member is fitted) into which the cup holder of the foamed resin part is fitted. Further, according to each of the above features, a novel technology related to an armrest (foamed resin molded article), its manufacturing method, and the mold used for manufacturing the foamed resin part is provided.

[0043] Although specific examples of the technology included in the claims are disclosed in this specification and the drawings, the technology described in the claims is not limited to these specific examples, and includes those obtained by variously modifying and changing the specific examples, and also includes those obtained by taking out a part from the specific examples alone. For example, a cup holder is a kind of container-like member, and an armrest is a kind of foamed resin molded article.

Explanation of Reference Numerals

[0044] 10 Armrest 12 Foamed resin part 12A Holder fitting recess 15 Skin material 20 Support frame 30 Cup holder 32 Cup receiving part 70 Foaming mold 71 Foaming raw material 77 Horizontal rib 78 Forming protrusion 79 Cavity

Claims

1. An armrest in which a holder fitting recess into which a cup holder is fitted is formed in a foamed resin portion of the armrest, The armrest having a horizontal groove extending in the width direction of the armrest on the inner surface of the holder fitting recess on the proximal end side of the armrest.

2. The armrest according to claim 1, wherein the horizontal groove is disposed at a position closer to the bottom surface in the depth direction of the holder fitting recess.

3. Comprising a support frame embedded in the foamed resin portion and attached to a vehicle, The armrest according to claim 1, wherein the horizontal groove is provided on the bottom surface side in the depth direction of the holder fitting recess rather than the support frame.

4. On the inner surface of the holder fitting recess, a pair of vertical grooves extending in the depth direction of the holder fitting recess are formed, and the horizontal groove communicates between the pair of vertical grooves. The armrest according to claim 1.

5. A method for manufacturing an armrest in which a holder fitting recess into which a cup holder is fitted is formed in a foamed resin portion of the armrest, A mold having a cavity in which the foamed resin portion is molded with the proximal end side of the armrest on top and the distal end side on the bottom is prepared, A horizontal rib extending in the width direction of the armrest is provided on the upper surface of the molding protrusion that forms the holder fitting recess in the mold, A method for manufacturing an armrest in which a foamed resin raw material is injected from above onto the upper surface of the molding protrusion to mold the foamed resin portion.

6. A mold for molding the foamed resin portion of an armrest in which a holder fitting recess into which a cup holder is fitted is formed in a foamed resin portion of the armrest, A cavity in which the foamed resin portion is molded with the proximal end side of the armrest on top and the distal end side on the bottom, A horizontal rib formed on the upper surface of the molding protrusion that forms the holder fitting recess in the mold and extending in the width direction of the armrest, And a raw material injection port capable of injecting a foamed resin raw material from above onto the upper surface of the molding protrusion.

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