Cushion pad for seat

Abstract

To prevent damage from occurring to a protrusion formed on a cushion pad for seat.SOLUTION: A cushion pad for seat 10 includes a first foam-molded body 12 and a second foam-molded body 14 disposed on the front side of the first foam-molded body 12. The first foam-molded body 12 includes a projection 16 protruding from the rear-side surface of the first foam-molded body 12, and a reinforcing material 18 which is at least partially embedded in the first foam-molded body 12 and reinforces the projection 16. The reinforcing material 18 is preferably disposed so as to extend from the projection 16 into the interior of the first foam-molded body 12 beyond the base of the projection 16 toward the front side.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] This invention relates to a seat cushion pad.

Background Art

[0002] In vehicle seats such as those in automobiles, the cushion pad that constitutes the seating part has been made of a soft polyurethane foam molded body so as to obtain comfortable cushioning properties. In recent years, however, in order to reduce weight, there has been a trend to arrange a bead foam such as polystyrene foam as a spacer in the lower layer. However, the bead foam undergoes molding shrinkage during its foam molding, and variations in dimensional accuracy are likely to occur. For this reason, since it is easy to fall off when the bead foam is attached to the mold, it has been proposed to form a raised portion on the bead foam and fit the raised portion into the mold (see, for example, Patent Document 1). In addition, in order to align the cushion pad with the frame of the vehicle body, a raised portion protruding from the bead foam may be provided.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As described above, when a raised portion is formed on the bead foam, there is a risk that the raised portion may be damaged when it hits another member during attachment to the mold, during conveyance of the cushion pad, or during attachment to the vehicle body.

[0005] In view of the above problems in the prior art, the present invention has been proposed to preferably solve these problems, and an object thereof is to provide a seat cushion pad having a protruding portion that is difficult to break.

Means for Solving the Problems

[0006] The first aspect of the seat cushion pad according to the present invention is a seat cushion pad including a first foamed body and a second foamed body disposed on the front side of the first foamed body, wherein the first foamed body has a protruding portion protruding from the back surface of the first foamed body, and includes a reinforcing material at least partially embedded in the first foamed body to reinforce the protruding portion.

[0007] The second aspect of the seat cushion pad according to the present invention is, in the first aspect, the reinforcing material may be disposed extending from the protruding portion across the inside of the first foamed body beyond the base of the protruding portion to the front side.

[0008] The third aspect of the seat cushion pad according to the present invention is, in the second aspect, the reinforcing material may be inserted from the tip of the protruding portion into the inside of the protruding portion.

[0009] The fourth aspect of the seat cushion pad according to the present invention is, in the second aspect, the reinforcing material may be inserted from the front surface of the first foamed body to the inside of the protruding portion.

[0010] The fifth aspect of the seat cushion pad according to the present invention is, in the second aspect, a part of the reinforcing material may be disposed along the side surface of the protruding portion.

[0011] The sixth aspect of the seat cushion pad according to the present invention is, in any one of the first aspect, the second aspect, the third aspect, the fourth aspect and the fifth aspect, the reinforcing material may have protrusions on the contact surface with the first foamed body.

[0012] The seventh aspect of the seat cushion pad according to the present invention is any one of the first aspect, the second aspect, the third aspect, the fourth aspect, the fifth aspect, and the sixth aspect, The reinforcing material may be a non-foamed resin.

Advantages of the Invention

[0013] According to the seat cushion pad of the present invention, the protruding portion is difficult to be damaged.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Modes for Carrying Out the Invention

[0015] Next, a preferred embodiment of the seat cushion pad according to the present invention will be described below with reference to the accompanying drawings. Note that the embodiments and drawings described below illustrate a part of the embodiments of the present invention, and are not used for the purpose of limiting to these configurations, and can be appropriately changed without departing from the gist of the present invention.

Example

[0016] (First Embodiment) The seat cushion pad 10 according to the first embodiment shown in FIG. 1 constitutes a seat surface portion in a vehicle such as an automobile, and supports the lower body of a user sitting on the seat. In the following description, the direction is referred to in the usage state of the seat cushion pad 10, the left - right direction corresponds to the vehicle width direction of the vehicle, the front - rear direction corresponds to the front - rear direction of the vehicle, and the front - back direction corresponds to the up - down direction. Note that the front side is up and the back side is down.

[0017] As shown in FIGS. 1 to 3, the seat cushion pad 10 includes a first foamed body 12 and a second foamed body 14. In the seat cushion pad 10, the second foamed body 14 is mainly disposed on the front side (upper side) of the first foamed body 12. In the seat cushion pad 10, the upper surface and the front, rear, left, and right side surfaces that the user touches are formed by the second foamed body 14, and the first foamed body 12 is exposed on the lower surface that the user does not touch.

[0018] The first foamed body 12 has a different material from the second foamed body 14. Also, the first foamed body 12 is formed of a material different from that of the second foamed body 14. The first foamed body 12 preferably has a lower density and is lighter than the second foamed body 14. Further, the first foamed body 12 is preferably harder than the second foamed body 14. As the first foamed body 12, for example, a bead foam obtained by a bead foaming method may be used. The bead foam is formed by pre-foaming raw material beads and then performing in-mold foaming. Examples of the bead foam include polystyrene foam, polypropylene foam, polyethylene foam, or those containing at least one of these. Since the bead foam with air bubbles sealed inside has a large part of its volume as gas, it is lightweight, and when used as the first foamed body 12, it has hardness and shape retention as a raised member constituting a part of the seat cushion pad 10.

[0019] The second foamed body 14 uses a foam obtained by a method that utilizes a chemical reaction such as gas generated by a polymerization reaction or a foaming agent, or a method of mixing air (mechanical mixing method) such as mechanically stirring and blowing in gas. As the second foamed body 14, for example, polyurethane foam can be adopted. Also, since the second foamed body 14 is on the user side when sitting on the seat, it is preferable to use a soft foam that is more flexible than the first foamed body 12.

[0020] As shown in FIGS. 2 and 3, the first foamed body 12 includes a protruding portion 16 that protrudes from the back surface thereof, and a reinforcing member 18 that is at least partially embedded in the first foamed body 12 and reinforces the protruding portion 16. The protruding portion 16 is a part of the first foamed body 12, and when particularly distinguishing the portion above the protruding portion 16 in the first foamed body 12, it is referred to as the main body portion 12a. In the embodiment, two protruding portions 16, 16 are formed on the back surface of the main body portion 12a in the first foamed body 12 at a distance in the left-right direction (see FIG. 2). Also, the protruding portion 16 is formed in a wall shape extending in the front-rear direction (see FIG. 3).

[0021] The reinforcing member 18 is harder than the first foamed molded body 12 and has higher rigidity than the first foamed molded body 12. As the reinforcing member 18, for example, a non-foamed resin (so-called solid resin), a metal, etc. are used alone or in combination, and among these, a non-foamed resin is preferable because it is lightweight.

[0022] The shape of the reinforcing member 18 is not particularly limited as long as it can be embedded in the first foamed molded body 12, but in the embodiment, it is rod-shaped. The contact surface (the circumferential surface in the embodiment) of the reinforcing member 18 that contacts the first foamed molded body 12 may be flat as in the embodiment (see Fig. 4(a)), or may have a protrusion 18a on the contact surface (circumferential surface) that contacts the first foamed molded body 12 as in the modified example (see Fig. 4(b)). When the contact surface (the circumferential surface in the embodiment) of the reinforcing member 18 that contacts the first foamed molded body 12 is flat as in the embodiment, the reinforcing member 18 can be easily attached to the first foamed molded body 12. Further, when the reinforcing member 18 has a protrusion 18a on the contact surface (circumferential surface) that contacts the first foamed molded body 12 as in the modified example, the protrusion 18a acts like a barb when the reinforcing member 18 is embedded in the first foamed molded body 12, so that the reinforcing member 18 can be made difficult to come off from the first foamed molded body 12. Note that reference numeral 20 is a pilot hole formed in advance in the first foamed molded body 12 for arranging the reinforcing member 18.

[0023] As shown in Figs. 2 and 3, the reinforcing member 18 is arranged across the inside of the main body portion 12a of the first foamed molded body 12 from the protruding portion 16 beyond the base of the protruding portion 16 to the front side. That is, the reinforcing member 18 is arranged across between the protruding portion 16 and the main body portion 12a in the first foamed molded body 12. Further, the reinforcing member 18 is inserted from the tip of the protruding portion 16 into the inside of the protruding portion 16. The reinforcing member 18 is formed longer than the protruding dimension of the protruding portion 16, and the reinforcing member 18 inserted from the tip of the protruding portion 16 into the inside of the protruding portion 16 reaches the inside of the main body portion 12a. The reinforcing member 18 is arranged at the center in the left-right direction of the protruding portion 16 (see Fig. 2). Further, in the protruding portion 16 formed long in the front-rear direction, a plurality (five in the embodiment) of the reinforcing members 18 are arranged apart in the front-rear direction (see Fig. 3).

[0024] An example of the manufacturing method of the seat cushion pad 10 described above will be described. The protruding portion 16 is fitted into the concave hole 32a provided in the upper mold 32 of the molding die 30, and the first foam molded body 12 is attached to the upper mold 32 (see Fig. 5(a)). The upper mold 32 and the lower mold 34 in the molding die 30 are closed (see Fig. 5(b)), and the second foam molded body 14 is formed by foaming and curing the foaming raw material in the cavity 30a formed inside the molding die 30 so as to overlap the first foam molded body 12 (see Fig. 5(c)). Next, the reinforcing material 18 is attached to the seat cushion pad 10 taken out from the molding die 30. The reinforcing material 18 is inserted into the lower hole 20 from the tip of the protruding portion 16 (see Fig. 4(a)), and the reinforcing material 18 is arranged so as to pass through the inside of the protruding portion 16 and reach the inside of the main body portion 12a (see Figs. 2 and 3). Thereby, the seat cushion pad 10 having the protruding portion 16 reinforced by the reinforcing material 18 is obtained.

[0025] As shown in Fig. 2, the seat cushion pad 10 is positioned by abutting the left and right protruding portions 16 against the vehicle body frame 100 and is attached to the vehicle body floor surface 102.

[0026] Since at least a part of the seat cushion pad 10 is embedded in the first foam molded body 12 and includes the reinforcing material 18 for reinforcing the protruding portion 16, it is possible to make the protruding portion 16 difficult to be damaged. In particular, in the seat cushion pad 10, by arranging the reinforcing material 18 across the inside of the first foam molded body 12 from the protruding portion 16 to beyond the base of the protruding portion 16 to the front side, the protruding portion 16 can be made more difficult to be damaged.

[0027] Since the protrusion 16 protrudes from the back surface of the seat cushion pad 10, it is likely to collide with the protrusion 16 in each handling scenario such as when transporting the seat cushion pad 10 or when attaching the seat cushion pad 10 to the vehicle body. In the seat cushion pad 10, since the protrusion 16 is reinforced by the reinforcing member 18, even if the protrusion 16 collides in the handling scenario of the seat cushion pad 10, it is possible to prevent the protrusion 16 from being damaged. Also, since the protrusion 16 is reinforced by the reinforcing member 18, it is easy to position by abutting against the vehicle body frame 100 when attaching the seat cushion pad 10 to the vehicle body. In the manufacturing method described above, the reinforcing member 18 was attached after the second foam molded body 14 was molded with the mold 30 to which the first foam molded body 12 was attached. However, if the reinforcing member 18 is attached to the first foam molded body 12 before the first foam molded body 12 is attached to the mold 30, it is possible to prevent the protrusion 16 from being damaged when the first foam molded body 12 is attached to the mold 30 or removed from the mold 30. Since the seat cushion pad 10 is less likely to have the protrusion 16 damaged, the work of repairing the damaged protrusion 16 that has conventionally occurred can be omitted, and the labor can be significantly reduced.

[0028] In the seat cushion pad 10, if the reinforcing member 18 is configured to be inserted from the tip of the protrusion 16 into the inside of the protrusion 16, the relatively weak tip side of the protrusion 16 can be reinforced by the reinforcing member 18, and the protrusion 16 can be made less likely to be damaged. Also, if the reinforcing member 18 is configured to be inserted from the tip of the protrusion 16 into the inside of the protrusion 16, the reinforcing member 18 can be attached after the second foam molded body 14 is molded with the mold 30 to which the first foam molded body 12 is attached.

[0029] (Second Embodiment) In the seat cushion pad 10 of the first embodiment, the reinforcing member 18 is inserted from the tip of the protruding portion 16 to the inside of the protruding portion 16. However, the present invention is not limited to this. As in the seat cushion pad 40 of the second embodiment shown in FIGS. 6 and 7, the reinforcing member 18 may be inserted from the front surface of the first foamed molded body 12 to the inside of the protruding portion 16. In the description of the second embodiment, members similar to those in the first embodiment are denoted by the same reference numerals as in the first embodiment, and the description thereof is omitted.

[0030] As shown in FIGS. 6 and 7, the reinforcing member 18 is disposed across the inside of the main body portion 12a of the first foamed molded body 12 from the protruding portion 16 beyond the base of the protruding portion 16 to the front side. That is, the reinforcing member 18 is disposed across between the protruding portion 16 and the main body portion 12a in the first foamed molded body 12. Further, the reinforcing member 18 is inserted from the front surface of the main body portion 12a of the first foamed molded body 12 to the inside of the protruding portion 16. The reinforcing member 18 is formed longer than the vertical dimension of the main body portion 12a of the first foamed molded body 12, and the reinforcing member 18 inserted into the main body portion 12a from the front surface of the main body portion 12a reaches the middle position in the vertical direction in the protruding portion 16. In the second embodiment, the reinforcing member 18 is attached to the first foamed molded body 12 before the first foamed molded body 12 is attached to the mold 30. And even in the seat cushion pad 40 of the second embodiment, the same operational effects as those in the first embodiment are achieved.

[0031] (Third Embodiment) In the first and second embodiments, the reinforcing member 18 is disposed inside the protruding portion 16 and the first foamed molded body 12. However, the present invention is not limited to this. As in the seat cushion pad 50 of the third embodiment shown in FIGS. 8 and 9, a part of the reinforcing member 18 may be disposed along the side surface of the protruding portion 16. In the description of the third embodiment, members similar to those in the first embodiment are denoted by the same reference numerals as in the first embodiment, and the description thereof is omitted.

[0032] As shown in FIGS. 8 and 9, the reinforcing member 18 of the third embodiment is formed in a shape of a square bracket in which one ends of the opposed bars are connected by a bar. The reinforcing member 18 is inserted into the main body portion 12a of the first foam molded body 12 along the side surface of the protruding portion 16 from the tip side of the protruding portion 16. More specifically, a part of the reinforcing member 18 on the closed end side abuts against the tip surface of the protruding portion 16 and is disposed sandwiching both side surfaces of the protruding portion 16, and the open end of the reinforcing member 18 is inserted into the main body portion 12a beyond the base of the protruding portion 16 to the front side. As shown in FIGS. 8 and 9, a groove 16a may be previously formed in the protruding portion 16 in accordance with the arrangement position of the reinforcing member 18. In the third embodiment, as in the second embodiment, the reinforcing member 18 may be attached to the first foam molded body 12 before attaching the first foam molded body 12 to the mold 30, or as in the first embodiment, after molding the second foam molded body 14. And the seat cushion pad 50 of the third embodiment also has the same effects as those of the first embodiment.

[0033] (Modification example) Not limited to the above-described matters, for example, it may be as follows. Note that the present invention is not limited only to the specific descriptions of the embodiments and the following modification examples. (1) The seat cushion pad may be used not only for vehicles such as automobiles but also for other things such as ships and airplanes. (2) The seat cushion pad may be not only the seat surface portion of the seat but also the backrest portion. (3) In the embodiment, a pilot hole was previously formed at the arrangement position of the reinforcing member in the first foam molded body and the protruding portion, but not limited thereto, the reinforcing member may be stabbed into the first foam molded body and / or the protruding portion. (4) Any two or more of the reinforcing members of the first embodiment, the second embodiment, and the third embodiment may be mixed.

Description of reference numerals

[0034] 10·40·50 Seat cushion pad, 12 First foam molded body, 14 Second foam molded body, 16 Protruding portion, 18 Reinforcing member

Claims

1. A seat cushion pad comprising a first foamed molded body and a second foamed molded body disposed on the front side of the first foamed molded body, wherein the first foamed molded body, has a protruding portion protruding from the back surface of the first foamed molded body, and a reinforcing material at least partially embedded in the first foamed molded body to reinforce the protruding portion. The seat cushion pad.

2. The seat cushion pad according to claim 1, wherein the reinforcing material is disposed from the protruding portion across the inside of the first foamed molded body beyond the base of the protruding portion to the front side.

3. The seat cushion pad according to claim 2, wherein the reinforcing material is inserted from the tip of the protruding portion into the inside of the protruding portion.

4. The seat cushion pad according to claim 2, wherein the reinforcing material is inserted from the front surface of the first foamed molded body to the inside of the protruding portion.

5. The seat cushion pad according to claim 2, wherein a part of the reinforcing material is disposed along the side surface of the protruding portion.

6. The seat cushion pad according to claim 1, wherein the reinforcing material has protrusions on the contact surface with the first foamed molded body.

7. The seat cushion pad according to claim 1, wherein the reinforcing material is a non-foamed resin.

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