Seat cushion pad

Abstract

To make projections formed on a seat cushion pad hard 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 second foam molded body 14 has a penetrating part 16 penetrating the first foam molded body 12 in a front-back direction, and a protruding part 18 connected via the penetrating part 16 and protruding to the back side of the first foam molded body 12. The seat cushion pad 10 further includes a reinforcement member 20 embedded from the inside of the penetrating part 16 to the inside of the protruding part 18.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a cushion pad for a seat. [Background technology]

[0002] In vehicle seats such as automobiles, the cushion pads that make up the seat have traditionally been made of soft polyurethane foam molded bodies to provide comfortable cushioning. However, in recent years, in order to reduce weight, there has been a growing trend to use foamed polystyrene beads or other foamed polystyrene beads as a lower layer to add bulk. However, foamed polystyrene beads tend to shrink during foam molding, resulting in variations in dimensional accuracy. Because foamed polystyrene beads tend to fall off when attached to a mold, it has been proposed to form raised portions on the foamed polystyrene beads and fit the raised portions into the mold (see, for example, Patent Document 1). Furthermore, cushion pads are sometimes provided with raised portions that protrude from the foamed polystyrene beads to align them with the vehicle frame. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-138634 Summary of the Invention [Problem to be solved by the invention]

[0004] As mentioned above, if a raised portion is formed on a bead foam, there is a risk that the raised portion may be damaged if it comes into contact with other parts when attaching the foam to a molding die, transporting the cushion pad, or attaching it to a vehicle body.

[0005] The present invention has been proposed in view of the above-mentioned problems associated with the conventional technology in order to solve these problems in an appropriate manner, and aims to provide a seat cushion pad having protrusions that are less likely to break. [Means for solving the problem]

[0006] A first aspect of the seat cushion pad according to the present invention is as follows: A seat cushion pad comprising a first foam molded body and a second foam molded body arranged on a front side of the first foam molded body, The second foam molded body is a through-hole penetrating the first foam molded body in the front-to-back direction; a protruding portion that is connected via the through portion and protrudes to the back side of the first foam molded body, The gist of the present invention is that a reinforcing material is embedded from the inside of the through portion to the inside of the protrusion.

[0007] A second aspect of the seat cushion pad according to the present invention is the same as the first aspect, The reinforcing material may be connected to a wire frame disposed on the outer surface of the front side of the first foam molded body.

[0008] A third aspect of the seat cushion pad according to the present invention is the same as the second aspect, The first foam molded body has a groove on the front surface thereof, The wire frame may be disposed in the groove, and a portion of the second foam molded body may be inserted in the groove.

[0009] A fourth aspect of the seat cushion pad according to the present invention is any one of the first aspect, the second aspect, and the third aspect, The second foam molded body may be softer than the first foam molded body. [Effects of the Invention]

[0010] According to the seat cushion pad of the present invention, the protruding portion is less likely to be damaged. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a perspective view of a seat cushion pad according to an embodiment of the present invention, viewed obliquely from above. [Figure 2]1 is a cross-sectional view showing a seat cushion pad according to an embodiment, cut in the front-rear direction. [Figure 3] FIG. 3 is a cross-sectional view taken along line AA in FIG. 2. [Figure 4] FIG. 4 is an enlarged view of part B in FIG. 3. [Figure 5] FIG. 3 is a cross-sectional view taken along line CC in FIG. 2. [Figure 6] FIG. 6 is an enlarged view of part D in FIG. 5. [Figure 7] 1A to 1C are explanatory diagrams showing a manufacturing process of the seat cushion pad of the embodiment. [Figure 8] 1A to 1C are explanatory diagrams showing a manufacturing process of the seat cushion pad of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] Next, the seat cushion pad according to the present invention will be described below by way of preferred embodiments with reference to the accompanying drawings. Note that the embodiments and drawings described below are intended to exemplify a portion of the embodiments of the present invention, and are not intended to limit the scope of the present invention to these configurations, and may be modified as appropriate within the scope of the gist of the present invention. [Example]

[0013] The seat cushion pad 10 according to the embodiment shown in Fig. 1 constitutes a seating surface portion of a vehicle such as an automobile, and supports the lower body of a user seated in the seat. In the following description, directions are indicated in the state in which the seat cushion pad 10 is in use, with the left-right direction corresponding to the width direction of the vehicle, the front-rear direction corresponding to the front-rear direction of the vehicle, and the front-rear direction corresponding to the up-down direction. The front side is the top and the back side is the bottom.

[0014] As shown in Figs. 1 to 5, 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 top surface and the front, rear, left and right side surfaces that come into contact with the user are formed of the second foam molded body 14, and the first foam molded body 12 is exposed on the bottom surface that the user does not touch.

[0015] The first foam molded body 12 is made of a different material than the second foam molded body 14. The first foam molded body 12 is preferably made of a different material than 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. The first foam molded body 12 is preferably harder than the second foam molded body 14. The first foam molded body 12 may be, for example, a bead foam obtained by a bead expansion method. The bead foam is formed by pre-expanding raw material beads and then in-mold foam molding. Examples of bead foams include polystyrene foam, expanded polypropylene, expanded polyethylene, and materials containing at least one of these. A bead foam with air bubbles sealed inside is lightweight because most of its volume is gas. When used as the first foam molded body 12, it has the hardness and shape retention required for a bulking member constituting part of the seat cushion pad 10.

[0016] The second foam molded body 14 is a foam obtained by a method utilizing a chemical reaction of gas generated by a polymerization reaction or a blowing agent, or by a method of incorporating air, such as mechanically stirring and blowing in gas (mechanical mixing method). Polyurethane foam, for example, can be used as the second foam molded body 14. Furthermore, since the second foam molded body 14 faces the user seated in the seat, it is preferable to use a soft foam that is more flexible than the first foam molded body 12. The second foam molded body 14 in the embodiment is softer than the first foam molded body 12.

[0017] 2 and 3, in the seat cushion pad 10, the second foam molded body 14 has a through-hole 16 that penetrates the first foam molded body 12 in the front-to-back direction, and a protruding portion 18 that is connected via the through-hole 16 and protrudes to the back side of the first foam molded body 12. The seat cushion pad 10 also has a reinforcing material 20 embedded from the inside of the through-hole 16 to the inside of the protruding portion 18.

[0018] As shown in FIGS. 2 and 3 , the through-holes 16 and the protruding portions 18 are parts of the second foam molded body 14, and when specifically distinguishing the parts of the second foam molded body 14 other than the through-holes 16 and the protruding portions 18, they are referred to as the main body portion 14a. The through-holes 12a are disposed in the through-holes 12a that penetrate the first foam molded body 12 in the front-to-back direction and are connected to the underside of the main body portion 14a of the second foam molded body 14. The through-holes 12a of the first foam molded body 12 extend from the front side to the back side of the first foam molded body 12. A portion of the second foam molded body 14 formed above the first foam molded body 12 enters the through-holes 12a, thereby forming the through-holes 16 in the part of the second foam molded body 14 that fills the through-holes 12a. The protruding portions 18 are formed below the through-holes 16 and are connected to the through-holes 16, and are connected to the main body portion 14a of the second foam molded body 14 via the through-holes 16. In the embodiment, protrusion 18 is formed as a wall extending in the front-to-rear direction on the rear surface of first foam molded body 12 (see FIG. 2). Also, two protrusions 18, 18 are formed on the rear surface of first foam molded body 12, spaced apart in the left-to-right direction (see FIGS. 3 and 5).

[0019] The reinforcing material 20 is preferably harder and more rigid than the first foam molded body 12 and the second foam molded body 14. Examples of the reinforcing material 20 include a non-foamed resin (so-called solid resin) and a metal, either alone or in combination. The reinforcing material 20 is connected to a wire frame 22 disposed on the outer surface of the front side of the first foam molded body 12 (see FIGS. 2 and 3). The shape of the reinforcing material 20 is not particularly limited as long as it can be disposed across the through-holes 16 and the protruding portions 18 of the first foam molded body 12, but in the present embodiment, the reinforcing material 20 is rod-shaped. The reinforcing material 20 of the present embodiment is formed in a concave shape that opens upward and has a vertical portion extending in the vertical direction (front-to-back direction) within the through-holes 16 and the protruding portions 18, and a horizontal portion extending in the horizontal direction (a direction intersecting the front-to-back direction) within the protruding portions 18 to connect the vertical portions (see FIG. 2). The through-holes 12a of the first foam molded body 12 are formed larger than the reinforcing material 20, and the inner walls of the through-holes 12a and the reinforcing material 20 are spaced apart.

[0020] As shown in FIGS. 2 and 3 , the reinforcing member 20 is disposed from the front side of the first foam molded body 12 to the inside of the protruding portion 18 beyond the rear surface of the first foam molded body 12. That is, the reinforcing member 20 passes vertically through the through-holes 12a of the first foam molded body 12 and is disposed between the through-holes 16 and the protruding portion 18. The vertical dimension of the reinforcing member 20 is longer than the vertical dimension of the first foam molded body 12, and the reinforcing member 20 inserted into the through-holes 12a from the front side of the first foam molded body 12 reaches the inside of the protruding portion 18. In the example, multiple vertical portions of the reinforcing member 20 (two in this embodiment) are disposed spaced apart in the front-rear direction in the protruding portion 18, which is elongated in the front-rear direction (see FIG. 2 ). The reinforcing member 20 is also disposed in the center of the protruding portion 18 in the left-right direction (see FIG. 3 ).

[0021] As shown in FIGS. 5 and 6 , the first foam molded body 12 has a groove 24 on its front surface. The groove 24 is recessed from the front side of the first foam molded body 12. The groove 24 has a narrow portion where the width of the upper opening on the front side is narrower than the width of the wire frame 22, and a normal 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. In this embodiment, a portion of the upper opening of the groove 24 is narrowed by the narrow portion disposed in the extension direction of the groove 24. The groove 24 is further formed to connect to the through hole 12a (see FIG. 2 ). The wire frame 22 is disposed in the groove 24. The interior of the groove 24 is larger than the wire frame 22, and the inner wall of the groove 24 is spaced apart from the wire frame 22. A portion of the second foam molded body 14 extends into the groove 24. That is, the space between the inner wall of groove 24 and wire frame 22 is filled with a part of second foam molded body 14 disposed above first foam molded body 12. Note that wire frame 22 may be provided with, in addition to reinforcing material 20, for example, a U-shaped fastening portion (not shown) for fastening to the vehicle body.

[0022] An example of a manufacturing method for the seat cushion pad 10 described above will be described. First, the reinforcing material 20 is inserted into the through-hole 12a of the first foam molded body 12, and the wire frame 22 connected to the reinforcing material 20 is placed in the groove 24 (see FIGS. 7(a) and 7(b)). In this embodiment, the groove 24 has an upper opening with a narrow portion that is narrower than the wire frame 22. Therefore, the wire frame 22 is inserted into the groove 24 while pushing open the upper opening at the narrow portion. When the wire frame 22 is placed in the groove 24, the upper opening at the narrow portion of the groove 24 returns to its original state, and the upper opening at the portion narrower than the wire frame 22 prevents the wire frame 22 from slipping out of the groove 24 (see FIG. 7(b)). This prevents the wire frame 22 and the reinforcing material 20 from coming off the first foam molded body 12 even when the first foam molded body 12 is turned upside down.

[0023] The first foam molded body 12 is attached to the upper mold 32 by placing the reinforcing member 20 protruding from the back surface of the first foam molded body 12 in a recessed hole 32a provided in the upper mold 32 of the molding die 30 (see FIG. 7(b)). The upper mold 32 and the lower mold 34 of the molding die 30 are then closed (see FIG. 8(a)), and the foaming raw material is foamed and cured in the cavity 30a formed inside the molding die 30, thereby forming the second foam molded body 14 superimposed on the first foam molded body 12 (see FIG. 8(b)). At this time, a portion of the foam that forms the second foam molded body 14 is filled into the recessed hole 32a via the through-holes 12a. Therefore, the part of second foam molded body 14 that has entered through hole 12a forms a through portion 16 in through hole 12a, and the periphery of reinforcing material 20 is covered by through portion 16, and the part of second foam molded body 14 that has entered recessed hole 32a forms a protruding portion 18 in recessed hole 32a, and the periphery of reinforcing material 20 is covered by protruding portion 18. In addition, part of the foam that forms second foam molded body 14 fills groove portion 24. Therefore, the part of second foam molded body 14 that has entered groove portion 24 fills the space between groove portion 24 and wire frame 22. In this way, a seat cushion pad 10 having protruding portion 18 reinforced by reinforcing material 20 is obtained.

[0024] As shown in FIGS. 3 and 5, the seat cushion pad 10 is positioned by abutting the left and right protrusions 18 against the vehicle body frame 100, and is then attached to the vehicle body floor surface 102.

[0025] In the seat cushion pad 10, the second foam molded body 14 has a through-hole 16 that penetrates the first foam molded body 12 in the front-to-back direction, and a protruding portion 18 that is connected via the through-hole 16 and protrudes to the back side of the first foam molded body 12. The seat cushion pad 10 also has a reinforcing material 20 embedded from the inside of the through-hole 16 to the inside of the protruding portion 18. Because the seat cushion pad 10 has the reinforcing material 20 disposed inside the protruding portion 18, the protruding portion 18 can be made less susceptible to damage. In particular, in the seat cushion pad 10, by disposing the reinforcing material 20 from the inside of the through-hole 16 that penetrates the first foam molded body 12 in the front-to-back direction to the inside of the protruding portion 18, the protruding portion 18 can be made more susceptible to damage.

[0026] Because the protrusion 18 protrudes from the back surface of the seat cushion pad 10, the protrusion 18 is likely to be hit when handling the seat cushion pad 10, such as when transporting the seat cushion pad 10 or when attaching the seat cushion pad 10 to a vehicle body. In the seat cushion pad 10, the protrusion 18 is reinforced by the reinforcing material 20, so that the protrusion 18 can be prevented from being damaged even if it is hit when handling the seat cushion pad 10. Furthermore, because the protrusion 18 is reinforced by the reinforcing material 20, it is easy to position the seat cushion pad 10 by abutting it against the vehicle body frame 100 when attaching it to the vehicle body. Furthermore, because the protrusion 18 of the seat cushion pad 10 is not likely to be damaged, the work of repairing a damaged protrusion 18, which has conventionally occurred, can be omitted, significantly reducing the amount of work required.

[0027] In the seat cushion pad 10, the reinforcing material 20 is disposed inside the through-holes 16 and protrusions 18 that are part of the second foam molded body 14, so that the second foam molded body 14 can position the reinforcing material 20 and prevent rattling of the reinforcing material 20. Furthermore, the second foam molded body 14 acts as a buffer, preventing noise and other problems caused by contact between the reinforcing material 20 and the first foam molded body 12.

[0028] Because reinforcing material 20 is connected to wire frame 22 arranged on the outer surface of the front side of first molded foam 12, it is easy to position reinforcing material 20 within through-hole 12a of first molded foam 12 and it is possible to improve the rigidity of reinforcing material 20. Furthermore, because reinforcing material 20 and wire frame 22 can be handled as a single unit, the work of attaching reinforcing material 20 to first molded foam 12 can be simplified.

[0029] By arranging the wire frame 22 in the groove 24 formed on the front surface of the first foam molded body 12, it becomes easy to position the wire frame 22 within the groove 24, and it also becomes easy to position the reinforcing material 20 within the through-hole 12a of the first foam molded body 12. In the seat cushion pad 10, since a portion of the second foam molded body 14 fits into the groove 24, the wire frame 22 can be positioned by the portion of the second foam molded body 14, preventing rattling of the wire frame 22. Furthermore, since the portion of the second foam molded body 14 acts as a buffer material, it is possible to prevent noise caused by contact between the wire frame 22 and the groove 24.

[0030] The second foam molded body 14 is softer than the first foam molded body 12, thereby improving the cushioning properties of the seat cushion pad 10. Furthermore, by covering the reinforcing material 20 with the through-holes 16 and protruding parts 18 made of the soft second foam molded body 14, the flexibility of the protruding parts 18 and through-holes 16 can cushion the impact of a collision by the protruding parts 18.

[0031] (Example of change) The present invention is not limited to the above-mentioned matters, but may be, for example, as follows: Note that the present invention is not limited to the specific descriptions of the embodiment and the following modified examples. (1) The seat cushion pad is not limited to use in vehicles such as automobiles, but may also be used in other applications such as ships and aircraft. (2) The seat cushion pad is not limited to the seat surface portion of the seat, but may also be used for the backrest portion. (3) In the embodiment, one reinforcing member is disposed in one penetration portion, but this is not limiting, and two or more reinforcing members may be disposed in one penetration portion. (4) In the embodiment, one reinforcing member is formed on one protruding portion, but this is not limiting, and two or more reinforcing members may be disposed on one protruding portion. (5) In the examples, the inner wall of the through hole and the reinforcing material are spaced apart, and a part of the second foamed molded body is interposed between the inner wall of the through hole and the reinforcing material, but this is not limited thereto, and the inner wall of the through hole and the reinforcing material may be in contact with each other. [Explanation of symbols]

[0032] 10 seat cushion pad, 12 first foam molded body, 14 second foam molded body, 16 penetration portion, 18 protrusion portion, 20 reinforcement material, 22 wire frame, 24 groove portion

Claims

1. A seat cushion pad comprising a first foam molded body and a second foam molded body arranged on a front side of the first foam molded body, The second foam molded body, A through-hole that penetrates the first foam molded body in the front-to-back direction; a protruding portion that is connected via the through portion and protrudes to the back side of the first foam molded body, A seat cushion pad comprising a reinforcing material embedded from inside the through portion to inside the protrusion.

2. The seat cushion pad according to claim 1 , wherein the reinforcing member is connected to a wire frame disposed on the outer surface of the first foam molding.

3. The first foam molded body has a groove on the front surface thereof, The seat cushion pad according to claim 2 , wherein the wire frame is disposed in the groove and a part of the second foam molded body is inserted in the groove.

4. 4. The seat cushion pad according to claim 1, wherein the second foam molded body is softer than the first foam molded body.

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