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; and recessed parts 18 each of which is formed ranging from a front surface of the first foam molded body 12 to the inside of the protruding part 16. The seat cushion pad 10 includes reinforcement materials 20 each of which is disposed ranging from the front side of the first foam molded body 12 to the inside of the recessed part 18 and reaches the inside of 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 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 in the lower layer for raising the height. 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 likely 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 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 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 and a concave portion formed from the front surface across the inside of the protruding portion, and the gist is to include a reinforcing material disposed from the front side of the first foamed body across the inside of the concave portion and reaching the inside of the protruding portion.

[0007] The second aspect of the seat cushion pad according to the present invention is, in the first aspect, a part of the second foamed body may enter the concave 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 reinforcing material may be connected to a wire frame disposed on the outer front surface of the first foamed body.

[0009] The fourth aspect of the seat cushion pad according to the present invention is, in the third aspect, the front surface of the first foamed body has a groove portion, wherein the groove portion is where the wire frame is disposed and a part of the second foamed body may enter.

[0010] The fifth 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, and the fourth aspect, the second foamed body may be softer than the first foamed body.

Advantages of the Invention

[0011] According to the seat cushion pad of the present invention, the protruding portion is difficult to be damaged.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Mode for Carrying Out the Invention

[0013] Next, the seat cushion pad according to the present invention will be described below with reference to the accompanying drawings by giving preferred embodiments. 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.

Embodiment

[0014] The seat cushion pad 10 according to the 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 directions are 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.

[0015] As shown in FIGS. 1 to 5, 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 where the user does not touch.

[0016] The first foamed body 12 has a different material from the second foamed body 14. Further, 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 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 a large part of its volume as gas, it is lightweight. When used as the first foamed body 12, it has hardness and shape retention as a raising member constituting a part of the seat cushion pad 10.

[0017] The second foamed body 14 uses a foam obtained by a method using 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 gas. As the second foamed body 14, for example, polyurethane foam can be adopted. Further, since the second foamed body 14 is on the user side sitting on the seat, it is preferable to use a soft foam that is more flexible than the first foamed body 12. The second foamed body 14 in the embodiment is softer than the first foamed body 12.

[0018] As shown in FIGS. 2 and 3, in the seat cushion pad 10, the first foam molded body 12 includes a protruding portion 16 that protrudes from the back surface of the first foam molded body 12, and a concave portion 18 that is formed from the front surface of the first foam molded body 12 across the inside of the protruding portion 16. Further, the seat cushion pad 10 includes a reinforcing member 20 that is disposed from the front side of the first foam molded body 12 across the inside of the concave portion 18 and reaches the inside of the protruding portion 16.

[0019] As shown in FIGS. 2 and 3, the protruding portion 16 is a part of the first foam molded body 12, and when particularly distinguishing the portion above the protruding portion 16 in the first foam molded body 12, it is referred to as the main body portion 12a. In the embodiment, the protruding portion 16 is formed in a wall shape extending in the front-rear direction on the back surface of the main body portion 12a in the first foam molded body 12 (see FIG. 2). Further, two protruding portions 16, 16 are formed on the back surface of the main body portion 12a in the first foam molded body 12 at a distance in the left-right direction (see FIGS. 3 and 5).

[0020] As shown in FIGS. 2 and 3, the concave portion 18 reaches from the front surface of the main body portion 12a of the first foam molded body 12 across the back surface to the inside of the protruding portion 16. Further, the concave portion 18 has a bottomed shape that opens on the front side of the main body portion 12a while the back side is closed (see FIG. 4). Furthermore, the concave portion 18 is formed larger than the reinforcing member 20, and the inner wall of the concave portion 18 and the reinforcing member 20 are separated. And a part of the second foam molded body 14 has entered the concave portion 18. That is, the space between the inner wall of the concave portion 18 and the reinforcing member 20 is filled with a part of the second foam molded body 14 disposed above the first foam molded body 12.

[0021] The reinforcing member 20 is harder and has higher rigidity than the first foam molded body 12, and for example, a non-foamed resin (so-called solid resin), metal, etc. are used alone or in combination as the reinforcing member 20. Further, the reinforcing member 20 is connected to a wire frame 22 disposed on the outer surface on the front side of the first foam molded body 12 (see FIGS. 2 and 3). The shape of the reinforcing member 20 is not particularly limited as long as it can be disposed in the recess 18 of the first foam molded body 12, but in the embodiment, it is rod-shaped. The reinforcing member 20 in the embodiment is formed in a concave shape that opens upward and has a vertical portion extending in the vertical direction (front-back direction) in the recess 18 and a horizontal portion extending in the horizontal direction (a direction intersecting the front-back direction) in the recess 18 and connecting between the vertical portions (see FIG. 2).

[0022] As shown in FIGS. 2 and 3, the reinforcing member 20 is disposed from the front side of the main body portion 12a in the first foam molded body 12 to extend into the inside of the protruding portion 16 that protrudes beyond the back side surface of the main body portion 12a to the back side. That is, the reinforcing member 20 is disposed across between the main body portion 12a and the protruding portion 16 in the first foam molded body 12. The vertical dimension of the reinforcing member 20 is formed longer than that of the main body portion 12a, and the reinforcing member 20 inserted into the recess 18 from the front side of the main body portion 12a reaches the inside of the protruding portion 16. The vertical portions of the reinforcing member 20 are arranged in the protruding portion 16 that is long in the front-rear direction, with a plurality (two in the embodiment) spaced apart in the front-rear direction (see FIG. 2). Further, the reinforcing member 20 is disposed at the center in the left-right direction of the protruding portion 16 (see FIGS. 3 and 4).

[0023] As shown in FIGS. 5 and 6, the first foamed molded body 12 has a groove portion 24 on the front surface thereof. The groove portion 24 is formed so as to be recessed from the front surface of the main body portion 12a in the first foamed molded body 12. Further, the groove portion 24 has a narrow-width portion where the width of the upper opening on the front side is narrower than the width of the wire frame 22, and a general portion where the width of the upper opening on the front side is equal to or greater than the width of the wire frame 22. Thus, in the embodiment, a part of the upper opening in the groove portion 24 is narrowed by the narrow-width portion arranged in the extending direction of the groove portion 24. In particular, it is preferable to form the narrow-width portion of the upper opening above the recess 18 because it facilitates positioning the reinforcing portion 20 arranged in the recess 18. Further, the groove portion 24 is formed in a range including the formation position of the recess 18, and a part of the groove portion 24 is connected to the recess 18 (see FIG. 2). And the wire frame 22 is arranged in the groove portion 24. The inside of the groove portion 24 is formed larger than the wire frame 22, and the inner wall of the groove portion 24 and the wire frame 22 are separated from each other. And a part of the second foamed molded body 14 has entered into the groove portion 24. That is, the space between the inner wall of the groove portion 24 and the wire frame 22 is filled with a part of the second foamed molded body 14 arranged above the first foamed molded body 12. Note that the wire frame 22 may be provided with, for example, a U-shaped fastening portion (not shown) for fastening to the vehicle body separately from the reinforcing material 20.

[0024] An example of the manufacturing method of the seat cushion pad 10 described above will be described. First, the reinforcing material 20 is inserted into the recess 18, and the wire frame 22 connected to the reinforcing material 20 is arranged in the groove portion 24 (see FIG. 7(a)). Since the upper opening of the groove portion 24 in the embodiment has a narrow-width portion that is narrower than the wire frame 22, the wire frame 22 is inserted into the groove portion 24 while pushing open the upper opening of the narrow-width portion. When the wire frame 22 is arranged in the groove portion 24, the upper opening of the narrow-width portion of the groove portion 24 returns to its original state, and the wire frame 22 is restricted from coming out of the groove portion 24 by the upper opening of the narrow-width portion that is narrower than the wire frame 22 (see FIG. 7(b)). Thereby, even if the first foamed molded body 12 is turned upside down, it is possible to prevent the wire frame 22 and the reinforcing material 20 from coming off.

[0025] The protruding portion 16 is fitted into the concave hole 32a provided in the upper mold 32 of the molding die 30 to attach the first foam molded body 12 to the upper mold 32 (see FIGS. 8(a) and 8(b)). The upper mold 32 and the lower mold 34 of the molding die 30 are closed (see FIG. 9(a)), 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 overlapping on the first foam molded body 12 (see FIG. 9(b)). At this time, a part of the foam body forming the second foam molded body 14 is filled in the groove portion 24 and the concave portion 18, and the space between the concave portion 18 and the reinforcing material 20 is filled by a part of the second foam molded body 14 that has entered the concave portion 18, and the space between the groove portion 24 and the wire frame 22 is filled by a part of the second foam molded body 14 that has entered the groove portion 24. Thereby, the seat cushion pad 10 having the protruding portion 16 reinforced by the reinforcing material 20 is obtained.

[0026] As shown in FIGS. 3 and 5, 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.

[0027] The seat cushion pad 10 includes a protruding portion 16 protruding from the back surface of the first foam molded body 12, a concave portion 18 formed from the front surface of the first foam molded body 12 across the inside of the protruding portion 16, and a reinforcing material 20 disposed from the front surface of the first foam molded body 12 across the inside of the concave portion 18 and reaching the inside of the protruding portion 16. Since the seat cushion pad 10 includes the reinforcing material 20 disposed inside 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 disposing the reinforcing material 20 so as to extend from the front surface of the first foam molded body 12 across the inside of the concave portion 18 and reach the inside of the protruding portion 16, it is possible to make the protruding portion 16 more difficult to be damaged.

[0028] Since the protruding portion 16 protrudes from the back surface of the seat cushion pad 10, it is likely to collide with the protruding portion 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 protruding portion 16 is reinforced by the reinforcing member 20, even if the protruding portion 16 is collided with in the handling scenario of the seat cushion pad 10, it is possible to prevent the protruding portion 16 from being damaged. Further, since the protruding portion 16 is reinforced by the reinforcing member 20, 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, it is possible to prevent the protruding portion 16 from being damaged when attaching the first foam molded body 12 to the mold 30 or when removing it from the mold 30. Since the protruding portion 16 of the seat cushion pad 10 is difficult to be damaged, the work of repairing the damaged protruding portion 16 that has conventionally occurred can be omitted, and the labor can be significantly reduced.

[0029] In the seat cushion pad 10, since a part of the second foam molded body 14 enters the recess 18, the reinforcing member 20 can be positioned by a part of the second foam molded body 14, and rattling of the reinforcing member 20 can be prevented. Further, since a part of the second foam molded body 14 acts as a cushioning material, generation of abnormal noise due to contact between the reinforcing member 20 and the recess 18 can be prevented.

[0030] Since the reinforcing member 20 is connected to the wire frame 22 disposed on the outer surface of the front side of the first foam molded body 12, positioning in the recess 18 becomes easy and the rigidity of the reinforcing member 20 can be improved. Further, since the reinforcing member 20 and the wire frame 22 can be handled integrally, the attachment work to the first foam molded body 12 can be simplified.

[0031] By disposing the wire frame 22 in the groove portion 24 formed on the front surface of the first foamed body 12, the positioning of the wire frame 22 in the groove portion 24 becomes easy, and the positioning of the reinforcing member 20 in the recess 18 becomes easy. In the seat cushion pad 10, since a part of the second foamed body 14 enters the groove portion 24, the wire frame 22 can be positioned by a part of the second foamed body 14, and rattling of the wire frame 22 can be prevented. Further, since a part of the second foamed body 14 acts as a cushioning material, generation of abnormal noise due to contact between the wire frame 22 and the groove portion 24 can be prevented.

[0032] Since the second foamed body 14 is softer than the first foamed body 12, the cushioning property of the seat cushion pad 10 can be improved. Further, the cushioning action of a part of the second foamed body 14 that has entered the recess 18 and / or the groove portion 24 can be improved.

[0033] (Modified example) Not limited to the above-described matters, for example, the following may be used. Note that the present invention is not limited to the specific descriptions of the embodiments and the following modified 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, one reinforcing member is disposed in one recess, but not limited thereto, two or more reinforcing members may be disposed in one recess. (4) In the embodiment, one recess is formed in one protrusion, but not limited thereto, two or more recesses may be formed in one protrusion. (5) In the embodiment, the inner wall of the recess and the reinforcing member are separated, and a part of the second foamed body is interposed between the inner wall of the recess and the reinforcing member. However, the present invention is not limited thereto, and the inner wall of the recess and the reinforcing member may be in contact with each other.

Explanation of reference numerals

[0034] 10-seat cushion pad, 12 first foam molded body, 14 second foam molded body, 16 protrusion, 18 recess, 20 reinforcing material, 22 wire frame, 24 groove portion

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 a recess formed from the front surface across the inside of the protruding portion, and the seat cushion pad includes a reinforcing member disposed from the front side of the first foamed molded body across the inside of the recess and reaching the inside of the protruding portion.

2. The seat cushion pad according to claim 1, wherein a part of the second foamed molded body enters the recess.

3. The seat cushion pad according to claim 2, wherein the reinforcing member is connected to a wire frame disposed on the outer front surface of the first foamed molded body.

4. The front surface of the first foamed molded body has a groove portion, and the seat cushion pad according to claim 3, wherein the wire frame is disposed in the groove portion and a part of the second foamed molded body enters the groove portion.

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

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