Seat cushion pad

Abstract

To make protruding parts formed at a seat cushion pad less likely to be damaged.SOLUTION: A seat cushion pad 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 has protruding parts 16 protruding from a rear surface of the first foam molded body 12. The seat cushion pad 10 includes foams 18 each of which is disposed along an outer surface of the protruding part 16. In the seat cushion pad 10, it is preferable that the foam 18 covers the protruding part 16.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 for 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 heightening material in the lower layer. However, the bead foam undergoes shrinkage during foam molding, and variations in dimensional accuracy are likely to occur. For this reason, since the bead foam is likely to fall off when 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 be damaged.

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 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, and the gist is to include a foam disposed along the outer surface of the protruding portion.

[0007] The second aspect of the seat cushion pad according to the present invention is, in the first aspect, the foam may cover the protruding portion.

[0008] The third aspect of the seat cushion pad according to the present invention is, in the first aspect or the second aspect, the first foamed molded body has a hole penetrating in the front-back direction, and the foam may be a part of the second foamed molded body disposed on the front side of the first foamed molded body and connected to the second foamed molded body through the hole.

[0009] The fourth aspect of the seat cushion pad according to the present invention is, in any one of the first aspect, the second aspect, and the third aspect, the first foamed molded body may be harder than the second foamed molded body.

Advantages of the Invention

[0010] According to the seat cushion pad of the present invention, the protruding portion is difficult to be damaged.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Best Mode for Carrying Out the Invention

[0012] Next, the seat cushion pad according to the present invention will be described below with reference to the accompanying drawings by giving preferred examples. 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.

Examples

[0013] (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, directions are referred to in the usage state of the seat cushion pad 10, where 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.

[0014] As shown in FIGS. 1 to 3, the seat cushion pad 10 includes a first foam molded body 12 and a second foam molded body 14. In the seat cushion pad 10, the second foam molded body 14 is mainly disposed on the front side (upper side) of the first foam molded 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 foam molded body 14, and the first foam molded body 12 is exposed on the lower surface where the user does not touch.

[0015] The first foam molded body 12 has a different material from the second foam molded body 14. Further, the first foam molded body 12 is formed of a different material from the second foam molded body 14. The first foam molded body 12 preferably has a lower density and is lighter than the second foam molded body 14. Also, the first foam molded body 12 is preferably harder than the second foam molded body 14. As the first foam molded 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 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 airtight bubbles inside has most of its volume as gas, it is lightweight, and when used as the first foam molded body 12, it has hardness and shape retention as a raising member constituting a part of the seat cushion pad 10.

[0016] The second foam molded 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 such as mechanically stirring and blowing in gas (mechanical mixing method). As the second foam molded body 14, for example, polyurethane foam can be adopted. Also, since the second foam molded 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 foam molded body 12.

[0017] As shown in FIGS. 2 and 3, the first foamed molded body 12 has a protruding portion 16 that protrudes from the back surface thereof. The protruding portion 16 is a part of the first foamed molded body 12, and when particularly distinguishing the portion above the protruding portion 16 in the first foamed molded 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 of the first foamed molded body 12 at a distance in the left - right direction (see FIG. 2). Further, the protruding portion 16 is formed in a wall shape extending in the front - rear direction (see FIG. 3).

[0018] As shown in FIGS. 2, 3 and 5, the seat cushion pad 10 includes a foam 18 disposed along the outer surface of the protruding portion 16. The foam 18 covers the front, rear, left and right side surfaces and the lower surface of the protruding portion 16, and the entire surface of the protruding portion 16 is covered with the foam 18. Thus, in the seat cushion pad 10, the protruding portion 15 protruding from the back surface of the seat cushion pad 10 is composed of the protruding portion 16 and the foam 18.

[0019] As shown in FIGS. 2 and 3, the first foamed molded body 12 has a hole portion 20 penetrating in the front - back direction (up - down direction in the embodiment). The upper opening of the hole portion 20 that opens on the upper surface of the main body portion 12a of the first foamed molded body 12 is located below the second foamed molded body 14 disposed above the main body portion 12a, and the lower opening of the hole portion 20 that opens on the lower surface of the main body portion 12a is located above the foam 18. As shown in FIG. 4, in the main body portion 12a of the first foamed molded body 12, a plurality of hole portions 20 are formed at intervals so as to surround the formation positions of the protruding portions 16.

[0020] As shown in FIGS. 2 and 3, the second foamed molded body 14 is disposed in the hole portion 20, and the second foamed molded body 14 disposed in the hole portion 20 is connected to the second foamed molded body 14 disposed on the front side (upper side) of the first foamed molded body 12. Thus, the foam 18 is connected to the second foamed molded body 14 disposed on the front side (upper side) of the first foamed molded body 12 via the second foamed molded body 14 disposed in the hole portion 20, and the foam 18 is a part of the second foamed molded body 14.

[0021] An example of the manufacturing method of the above-described seat cushion pad 10 will be described. The protruding portion 16 is inserted 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. 6(a)). The upper mold 32 and the lower mold 34 in the molding die 30 are closed (see Fig. 6(b)), and the foam raw material is foamed and cured in the cavity 30a formed inside the molding die 30, so that the second foam molded body 14 is formed by being overlaid on the first foam molded body 12 (see Fig. 6(c)). At this time, a part of the foam raw material passes through the hole portion 20 of the first foam molded body 12 and is foamed and cured in the concave hole 32a, so that the hole portion 20 is filled with the second foam molded body 14 and the foam body 18 is formed along the outer surface of the protruding portion 16. Thereby, the seat cushion pad 10 in which the foam body 18 is arranged along the outer surface of the protruding portion 16 formed by the first foam molded body 12 is obtained.

[0022] As shown in Fig. 2, the seat cushion pad 10 is positioned by applying the left and right protrusions 15 against the vehicle body frame 100 and is attached to the vehicle body floor surface 102. At this time, in the protrusion 15, the foam body 18 arranged along the outer surface of the protruding portion 16 hits the vehicle body frame 100.

[0023] Since the protrusion 15 protrudes from the back surface of the seat cushion pad 10, it is easy to hit the protrusion 15 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, the protrusion 15 is formed by a protruding portion 16 that protrudes from the back surface of the first foam molded body 12 and a foam body 18 that is disposed along the outer surface of the protruding portion 16 formed by the first foam molded body 12. In this way, since the protrusion 15 protruding from the back surface of the seat cushion pad 10 includes the protruding portion 16 and the foam body 18, it is possible to make it difficult to damage the protrusion 15 (protruding portion 16). Here, if the protruding portion 16 is formed of the first foam molded body 12 that is harder than the foam body 18 and the foam body 18 that is softer than the protruding portion 16 is disposed along the outer surface of the protruding portion 16, the protruding portion 16 can be protected by the foam body 18, and when the protrusion 15 collides, it can be buffered by the foam body 18. In particular, since the foam body 18 covers the protruding portion 16, it becomes easier to buffer the impact applied to the protruding portion 16 with the foam body 18, and it is possible to make it more difficult to damage the protruding portion 16 (protrusion 15). Further, when attaching the seat cushion pad 10 to the vehicle body, it is easy to position by applying the protrusion 15 against the vehicle body frame 100.

[0024] In the seat cushion pad 10, the foam body 18 is a part of the second foam molded body 14 that is connected to the second foam molded body 14 disposed on the front side of the first foam molded body 12 through the hole portion 20 of the first foam molded body 12. In this way, since the second foam molded body 14 and the foam body 18 disposed along the protruding portion 16 are connected, it is possible to make it difficult for the foam body 18 to come off from the protruding portion 16. Further, when foaming the second foam molded body 14, the foam body 18 can be foam molded on the outer surface of the protruding portion 16, and the foam body 18 can be easily formed.

[0025] (Second Embodiment) In the seat cushion pad 10 of the first embodiment, the front, rear, left, right, and lower surfaces of the protruding portion 16 are covered with the foam 18. However, the present invention is not limited to this. As in the seat cushion pad 40 of the second embodiment shown in FIGS. 7 to 10, a part of the protruding portion 16 may be covered with the foam 18. 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.

[0026] As shown in FIGS. 7 and 10, the seat cushion pad 40 includes a foam 18 disposed along one surface of the outer surface of the protruding portion 16. The foam 18 covers only the outer side surfaces in the left - right direction of the protruding portion 16, and the inner side surfaces in the left - right direction, the front - rear side surfaces, and the lower surface of the protruding portion 16 are exposed. When attaching the seat cushion pad 40 to the vehicle body, it is preferable that the foam 18 exists on the surface of the protrusion 15 that contacts the vehicle body frame 100. And even the seat cushion pad 40 of the second embodiment exhibits the same operational effects as those of the first embodiment.

[0027] (Modification example) Not limited to the matters described above, for example, the following may be adopted. 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 for the seat surface portion of the seat but also for the backrest portion. (3) The foam in the embodiment is a part of the second foam - molded body. However, the present invention is not limited to this, and the foam may be separate from the second foam - molded body. For example, a foam softer than the first foam - molded body, such as slab urethane, may be attached or wound around the protruding portion of the first foam - molded body, or a separate body from the second foam - molded body may be arranged.

Description of reference numerals

[0028] 10·40 Seat cushion pad, 12 First foam - molded body, 14 Second foam molded body, 16 Protrusion, 18 Foam, 20 Hole part

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, and the seat cushion pad includes a foam disposed along the outer surface of the protruding portion.

2. The seat cushion pad according to claim 1, wherein the foam covers the protruding portion.

3. The first foamed molded body has a hole penetrating in the front-back direction, and the seat cushion pad according to claim 1, wherein the foam is a part of the second foamed molded body connected to the second foamed molded body disposed on the front side of the first foamed molded body through the hole.

4. The seat cushion pad according to any one of claims 1 to 3, wherein the first foamed molded body is harder than the second foamed molded body.

Images