Seat pad

Abstract

To provide reinforcement measures because there may be a problem that a side support part makes it easy to fall outwards with conventional seat pad.SOLUTION: In seat pad that a side edge part of the seat pad protrudes on side front and then is formed as a side support part supporting a seating person from a lateral direction, the seat pad is formed from reverse face of the side support part over inside and is provided with a reinforcement member reception part into which a tubular reinforcement member is inserted.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a seat pad. [Background technology]

[0002] BACKGROUND ART Known conventional seat pads have side edges that protrude outward to form side support portions that support a seated person from the sides (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2016-94072 (Fig. 2, etc.) Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional seat pads described above, the side support portions can easily collapse outward, and so reinforcement measures are needed to address this issue. In particular, when the side support portions are thin in design (when the side support portions are designed with a thin thickness in the width direction), the side support portions tend to collapse outward, and measures are needed to address this issue. [Means for solving the problem]

[0005] One aspect of the invention is a seat pad in which the side edge of the seat pad protrudes outward to form a side support portion that supports the seated occupant from the side, and which is provided with a reinforcing member receiving portion that is formed from the back surface of the side support portion to the interior and into which a plate-shaped reinforcing member is inserted. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a front perspective view of a seat on which a seat pad is provided. [Figure 2] Figure 2 is a cross-sectional view of the seat pad. [Figure 3] Figure 3 is a cross-sectional view of the molding die in a closed state. [Figure 4] Figure 4 shows a cross section of a foam-molded seat pad in a mold. [Figure 5] FIG. 5A is a cross-sectional view of a plate-shaped reinforcing member inserted into a reinforcing member receiving portion, and FIG. 5B is a cross-sectional view of the plate-shaped reinforcing member inserted into the reinforcing member receiving portion. [Figure 6] FIG. 6 is a plan cross-sectional view of another example of a seat pad. [Figure 7] FIG. 7 is a cross-sectional view of a side support portion of a seat pad according to another embodiment. [Figure 8] FIG. 8 is a cross-sectional view of a side support portion of a seat pad according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] [First embodiment] As shown in Figures 1 and 2, the seat pad 10 of this embodiment is a back pad used in a backrest portion 92 (seat back) of a seat 90. In the example of this embodiment, the seat 90 is for a front seat of a vehicle, but it may also be for a rear seat. The seat 90 to which the seat pad 10 is applied may be for a vehicle other than a vehicle, or may be for a building. For example, the backrest portion 92 is configured such that the seat pad 10 is covered with a cover 93.

[0008] The side edge portions of the seat pad 10 protrude toward the front side (the lower side in FIG. 2) to form side support portions 20 that support the seated occupant from the sides. In this embodiment, the side support portions 20 are provided on both side edge portions of the seat pad 10 in the width direction.

[0009] A rear recess 21 is formed on the rear surface of the side support portion 20 of the rear surface of the seat pad 10 (the upper surface in FIG. 2 ). A rear protrusion 22 that protrudes rearward is formed on the edge of the rear surface of the seat pad 10 (the rear surface of the side support portion 20) that is outer than the rear recess 21. A flange portion 23 that bends inward (inward when viewed from the rear side) and faces the rear recess 21 from the rear side is formed at the protruding tip of the rear protrusion 22. A frame receiving portion 24 that receives a back frame that supports the seat pad 10 is formed by the rear recess 21 and the portions of the rear surface of the seat pad 10 between the rear protrusions 22 on both sides in the width direction of the seat pad 10.

[0010] In this embodiment, the seat pad 10 includes a seat pad main body 11 that is an elastic resin molded body (for example, a foamed resin molded body) and has side support portions 20 at its side edges, and a back surface material 30 that is laminated and integrated with the back surface of the seat pad main body 11. In this embodiment, the back surface material 30 is disposed on the inner surface of the frame receiving portion 24 on the back surface of the seat pad 10. In this embodiment, the back surface material 30 is made of nonwoven fabric, but is not limited to this and may be a resin film or the like.

[0011] However, in a seat pad equipped with side support portions, the side support portions (especially those that are thin in the width direction) can easily collapse outward, which can result in a loss of support feeling from the seat pad or noise caused by the side support portions hitting surrounding components (such as the center console).

[0012] In contrast, the seat pad 10 of this embodiment has the following characteristic configuration. Specifically, the seat pad 10 is provided with a reinforcing member receiving portion 25 that is formed from the rear surface of the side support portion 20 to the interior thereof and into which a plate-shaped reinforcing member 40 is inserted (see FIG. 5A). Therefore, by inserting the plate-shaped reinforcing member 40 into the reinforcing member receiving portion 25 (see FIG. 5B), the side support portion 20 can be reinforced and the durability of the side support portion 20 can also be improved. This makes it possible to prevent the side support portion 20 from easily collapsing outward.

[0013] In this embodiment, the reinforcing member receiving portion 25 is a groove. The reinforcing member receiving portion 25 is provided from the bottom surface of the rear recess 21 on the rear surface of the side support 20 (for example, from the outer end of the bottom surface in the width direction of the seat pad 10) to the inside of the side support portion 20.

[0014] In this embodiment, the plate-shaped reinforcing member 40 is disposed so that its thickness direction coincides with the width direction of the seat pad 10 (width direction of the side support portion 20). The plate-shaped reinforcing member 40 has, for example, a long plate shape extending in the longitudinal direction of the side support portion 20, and may have a shape that bulges outward to match the shape of the side support portion 20 that bulges outward (see FIG. 1). The reinforcing member receiving portion 25 has, for example, an inner surface shaped to match the outer shape of the plate-shaped reinforcing member 40.

[0015] The plate-shaped reinforcing member 40 is made of, for example, a material that is harder or more rigid than the seat pad main body 11. In the example of this embodiment, the plate-shaped reinforcing member 40 is a pressed felt, but is not limited to this and may be made of other fiber aggregates (for example, a fiber aggregate made of resin). The plate-shaped reinforcing member 40 may be made of resin or metal. For example, if the seat pad main body 11 is made of foamed resin, the plate-shaped reinforcing member 40 may be made of a resin (for example, foamed resin) that has a higher density (apparent density) than the seat pad main body 11. Note that if the seat pad main body 11 is made of foamed resin and the plate-shaped reinforcing member 40 is made of press felt, it is possible to reinforce the side support portions 20 while ensuring the cushioning properties of the side support portions 20.

[0016] In this embodiment, the back surface material 30 is provided with a pocket portion 35 that covers the inner surface of the reinforcing member receiving portion 25 and receives the plate-shaped reinforcing member 40. For example, the pocket portion 35 is extended (for example, sewn) from a portion of the back surface material 30 that is layered on the back surface of the side support portion 20.

[0017] In the example of this embodiment, the plate-shaped reinforcing member 40 is press-fitted into the reinforcing member receiving portion 25, and is provided in the seat pad 10 in a state in which the plate-shaped reinforcing member 40 is pressed against the inner surface of the reinforcing member receiving portion 25 from both sides in the thickness direction of the plate-shaped reinforcing member 40 by the elastic force of the seat pad main body portion 11. The original thickness of the plate-shaped reinforcing member 40 before being inserted into the reinforcing member receiving portion 25 is thicker than the distance between opposing surfaces of the inner surface of the reinforcing member receiving portion 25 that sandwich the plate-shaped reinforcing member 40 in the thickness direction (in the example of this embodiment, the original thickness is thicker than the distance between opposing surfaces of the pocket portion 35 that sandwich the plate-shaped reinforcing member 40).

[0018] The seat pad 10 of this embodiment is manufactured, for example, as follows. Fig. 3 shows a molding die 50 for molding the seat pad 10. The molding die 50 has a plurality of split dies. In this embodiment, the split dies include a lower die 51, an upper die 52, and a middle die 60 attached to the upper die 52. Note that this embodiment is merely an example of the configuration of the molding die 50, and the configuration of the molding die 50 (such as the split die configuration and die opening direction) is not limited to this.

[0019] In the mold closed state, the lower mold 51 and the upper mold 52 are overlapped and abutted in the vertical direction, and in the mold open state, the upper mold 52 and the lower mold 51 are separated. The lower mold 51 has a molding recess 51U that is open upward. The upper mold 52 is shaped like a lid that closes the molding recess 51U of the lower mold 51. In the mold closed state, the molding recess 51U of the lower mold 51 is closed by the upper mold 52, thereby forming a cavity 55 inside the molding die 50 into which the seat pad 10 is molded. A fitting opening 52K into which the middle mold 60 is fitted is formed in the center of the lower surface of the upper mold 52.

[0020] The intermediate die 60 is fitted into the fitting opening 52K of the upper die 52 and attached. In the closed state, the intermediate die 60 protrudes from the lower surface of the upper die 52 into the cavity 55 (inside the molding recess 51U) and is disposed at a distance from the inner surface of the molding recess 51U. The intermediate die 60 has a protruding portion 61 on the side portion protruding from the upper die 52. The protruding portion 61 protrudes laterally (in a direction intersecting the protruding direction) beyond a base end portion 62 of the intermediate die 60 that is fitted into the fitting opening 52K, and is disposed at a distance from the molding surface (lower surface) of the upper die 52. The tip side portion of the intermediate die 60, including the protruding portion 61, is a portion that forms the inner surface of the frame receiving portion 24 of the seat pad 10 (seat pad main body portion 11).

[0021] A molding protrusion 64 that protrudes downward is provided on the side edge portion of the overhanging portion 61 (both side edge portions in this embodiment). The molding protrusion 64 is a portion that forms the rear side recess 21 of the seat pad 10 (seat pad main body portion 11). A plate-like protrusion 63 protrudes from the protruding tip of the molding protrusion 64. The plate-like protrusion 63 is a portion that forms the reinforcing member receiving portion 25 of the seat pad 10 (seat pad main body portion 11).

[0022] In this embodiment, the back surface material 30 is set so as to cover the protruding portion 61 of the middle mold 60 (i.e., so as to cover the forming protrusion 64 and the plate-like protrusion 63 as well). A pocket portion 35 is formed in the back surface material 30 in advance, and the pocket portion 35 is placed over the plate-like protrusion 63.

[0023] In this embodiment, a foaming resin (such as polyurethane resin) raw material G is injected into the molding die 50, and when the raw material G foams and hardens, the seat pad 10 is molded in the cavity 55 (see FIG. 4). At this time, the frame receiving portion 24 of the seat pad 10 is molded by the middle die 60, and the rear recess 21 is molded by the molding protrusion 64. Furthermore, the reinforcing member receiving portion 25 is molded by the plate-like protrusion 63. Then, the molding die 50 is opened, and the seat pad 10 is demolded.

[0024] Next, as shown in FIG. 5A, the plate-shaped reinforcing member 40 is inserted into the reinforcing member receiving portion 25. In this embodiment, the thickness of the plate-shaped reinforcing member 40 is greater than the groove width of the reinforcing member receiving portion 25, and the plate-shaped reinforcing member 40 is press-fitted into the reinforcing member receiving portion 25 (in this embodiment, the plate-shaped reinforcing member 40 is press-fitted into the pocket portion 35 of the back surface material 30; see FIG. 5B). By press-fitting the plate-shaped reinforcing member 40 into the reinforcing member receiving portion 25 in this manner, the plate-shaped reinforcing member 40 is less likely to come off the reinforcing member receiving portion 25. Note that when the back frame is received and attached in the frame receiving portion 24 of the seat pad 10, a portion of the back frame is received in the rear-side recess 21 and covers the opening of the reinforcing member receiving portion 25, making it possible to prevent the plate-shaped reinforcing member 40 from coming off the reinforcing member receiving portion 25. However, in the example of this embodiment, the plate-shaped reinforcing member 40 is pressed into the reinforcing member receiving portion 25, making it possible to prevent the plate-shaped reinforcing member 40 from coming out of the reinforcing member receiving portion 25 even until the seat pad 10 is attached to the back frame.

[0025] To reinforce the side support portions of the seat pad, one possible configuration is to mold the side support portions integrally with plate-shaped reinforcing members and embed the plate-shaped reinforcing members in the side support portions. In this case, the plate-shaped reinforcing members are attached so as to hang from the middle mold (the middle molded protrusion 64 that does not have the plate-shaped protrusion 63) of the molding die 50. With this method, there is a risk that the position of the plate-shaped reinforcing members may shift or the plate-shaped reinforcing members may fall over due to the resin pressure during molding of the seat pad, resulting in the plate-shaped reinforcing members being embedded in an inclined state. If the plate-shaped reinforcing members are embedded in the side support portions in an inclined state, some of the members may be exposed or the feel may be poor. In contrast, in the manufacturing method of the seat pad 10 of this embodiment, the reinforcing material receiving portion 25 is formed using the plate-shaped protrusion 63 of the molding die 50, and after the seat pad main body portion 11 is formed (after the side support portion 20 is formed), the reinforcing material (plate-shaped reinforcing material 40) can be inserted into the reinforcing material receiving portion 25, thereby making it possible to prevent the plate-shaped reinforcing material from being buried with its posture tilted or misaligned.

[0026] In the seat pad 10, the reinforcing member receiving portion 25 may be provided on both side support portions 20 (see FIG. 2) or only on one side support portion 20 (see FIG. 6). For example, if the side support portions 20 having the reinforcing member receiving portion 25 are provided on the side edge portions of the seat pad 10 located toward the center of the vehicle, reinforcing the side support portions 20 with the plate-shaped reinforcing member 40 can prevent the side support portions 20 from falling outward and hitting components such as the center console, thereby preventing abnormal noise. In addition, in a configuration in which the side support portions 20 having the reinforcing member receiving portion 25 are provided only on the side edge portions of the seat pad 10 located toward the center of the vehicle, an airbag device 98 can be received in the back-side recess 21 of the door-side side support portion 20. In this case, for example, a groove that thins the side support portion 20 is formed in the bottom surface of the back-side recess 21 to make it easier for an airbag to tear the side support portion 20 and project forward.

[0027] [Other embodiments] In the seat pad 10 of the above embodiment, the reinforcing member receiving portion 25 is groove-shaped, but the reinforcing member receiving portion 25 may be a slit, and the plate-shaped reinforcing member 40 may be inserted (e.g., pressed into) this slit. When the seat pad 10 is provided with a back surface material 30, the pocket portion 35 of the back surface material 30 may be received in the slit, and the plate-shaped reinforcing member 40 may be inserted inside the pocket portion 35. Alternatively, for example, no pocket portion 35 may be provided, and a slit through which the plate-shaped reinforcing member 40 passes may be formed in the back surface material 30 at a position that overlaps with the slit in the seat pad main body portion 11. These slits can be formed, for example, with a cutter or the like after foam molding of the side support portion 20 (of the seat pad main body portion 11).

[0028] In the above embodiment, the seat pad 10 having the reinforcing member receiving portion 25 into which the plate-shaped reinforcing member 40 is inserted is applied to a back pad used in the backrest portion 92 (seat back) of the seat 90. However, the seat pad 10 may also be applied to a cushion pad used in the seating portion 91 (see FIG. 1) of the seat 90. In this case, the side edge portions of the cushion pad protrude to the front side (upper side) to form side support portions 20V (see FIG. 1) that support the seated occupant, and a reinforcing member receiving portion (e.g., a groove or notch) may be provided extending from the back surface of the side support portion 20V to the interior, into which the plate-shaped reinforcing member 40 is inserted. In the example shown in FIG. 1, the seat 90 is for a front seat of a vehicle, but it may also be for a rear seat. The seat 90 may also be for a vehicle other than a vehicle, or for a building. For example, the seating portion 91 is configured such that the cushion pad is covered with a cover.

[0029] The seat pad 10 does not necessarily have to be provided with the back surface material 30 (see FIG. 7).

[0030] As shown in FIG. 7 , a retaining protrusion 29 may be provided that protrudes from the inner surface of the reinforcing member receiving portion 25 or the back surface of the side support portion 20 and catches on the plate-shaped reinforcing member 40, thereby retaining the plate-shaped reinforcing member 40 within the reinforcing member receiving portion 25. The retaining protrusion 29 may protrude, for example, in a direction intersecting the depth direction of the reinforcing member receiving portion 25, thereby narrowing the opening of the reinforcing member receiving portion 25. Such a retaining protrusion 29 may protrude from the back surface material 30 (e.g., the pocket portion 35). For example, the retaining protrusion 29 may protrude from both opposing portions of the side support portion 20 or the back surface material 30 that face each other across the reinforcing member receiving portion 25, or may protrude from only one of them. Alternatively, a through hole penetrating the plate-shaped reinforcing member 40 in the thickness direction may be formed, and such a retaining protrusion 29 may be inserted into and engaged with the through hole. The plate-shaped reinforcing member 40 may be configured to be able to be stuck into the bottom of the reinforcing member receiving portion 25, and by sticking it in this way, the plate-shaped reinforcing member 40 may be prevented from coming off.

[0031] In a configuration in which the plate-shaped reinforcing member 40 is received in the pocket portion 35 of the backing material 30, a tongue piece 48 may be formed on the backing material 30, which is inserted between the opening edges of the pocket portion 35 to cover the opening (for example, to connect the opening edges). For example, the tongue piece 48 is sewn to one of the opposing opening edges of the pocket portion 35 and extends to the other opening edge (for example, fixed to this opening edge by adhesive or the like). Covering the opening of the pocket portion 35 with the tongue piece 48 makes it possible to prevent the plate-shaped reinforcing member 40 from slipping out of the reinforcing member receiving portion 25.

[0032] In the above embodiment, the plate-shaped reinforcing member 40 may be a reinforcing member that is not plate-shaped.

[0033] <Additional Notes> The following describes the group of features extracted from the above embodiment, highlighting their effects as necessary.

[0034] For example, the following features of the present disclosure can be considered to have been conceived in response to the following problem in relation to seat pads: "Conventional seat pads are known in which side edges protrude outward to form side support portions that support the seated occupant from the sides (see, for example, JP 2016-94072 A (Figure 2, etc.))." The following background art states that "In the above-described conventional seat pads, the side support portions can easily collapse outward, and therefore reinforcement measures are required. In particular, if the side support portions are thin in design (if the side support portions are designed with a thin width), the side support portions tend to collapse outward, and measures are therefore required." Furthermore, there has long been a need for the development of new technologies related to seat pads and their manufacturing methods.

[0035] [Feature 1] A seat pad in which the side edge portions of the seat pad protrude outward to form side support portions that support the seated person from the sides, The seat pad is provided with a reinforcing member receiving portion formed from the rear surface of the side support portion to the interior thereof, into which a plate-shaped reinforcing member is inserted.

[0036] [Feature 2] A backing material covering the back surface of the side support portion is provided, 2. The seat pad according to claim 1, wherein the backing material is provided with a pocket portion that covers the inner surface of the reinforcing member receiving portion and receives the plate-shaped reinforcing member.

[0037] [Feature 3] The seat pad according to Feature 2, wherein the back surface material is provided with a tongue piece connecting the opening edges of the pocket portion.

[0038] [Feature 4] A seat pad according to any one of features 1 to 3, wherein the plate-shaped reinforcing member is provided within the reinforcing member receiving portion.

[0039] [Feature 5] 5. The seat pad according to claim 4, wherein the plate-shaped reinforcing member is press-fitted into the reinforcing member receiving portion.

[0040] [Feature 6] 6. The seat pad according to claim 4 or 5, wherein the plate-like reinforcing member is a press felt.

[0041] [Feature 7] A seat pad described in any one of features 1 to 6, which is provided with a slip-out prevention protrusion that protrudes from the inner surface of the reinforcing member receiving portion or the back surface of the side support portion, and is capable of hooking onto the plate-shaped reinforcing member and retaining the plate-shaped reinforcing member within the reinforcing member receiving portion.

[0042] [Feature 8] A seat pad according to any one of features 1 to 7, wherein the side support portion having the reinforcing member receiving portion is provided only on the side edge portion located on the center side of the vehicle.

[0043] [Feature 9] The seat pad according to any one of Features 1 to 8, wherein the reinforcing member receiving portion is groove-shaped.

[0044] In Feature 1, the reinforcing member receiving portion into which the plate-shaped reinforcing member is inserted is formed from the rear surface of the side support portion to the interior thereof. Therefore, by inserting the plate-shaped reinforcing member, it becomes possible to reinforce the side support portion with the plate-shaped reinforcing member, and it becomes possible to prevent the side support portion from easily collapsing outward.

[0045] Here, one option for reinforcing the side support portions is to mold the side support portions with reinforcing members embedded in them, but in this case, there is a risk that the position of the reinforcing member may shift due to the resin pressure during molding, or that the plate-shaped reinforcing member may tilt, resulting in the plate-shaped reinforcing member being embedded at an angle (plate-shaped reinforcing members are particularly prone to being embedded at an angle). In contrast, with Feature 1, the reinforcing member can be inserted into the reinforcing member receiving portion after the side support portions are molded, making it possible to prevent the reinforcing member from shifting in position or being embedded at an angle.

[0046] In feature 3, the back surface material is provided with a tongue piece that connects the opening edges of the pocket portion, making it possible to prevent the plate-shaped reinforcing member inserted into the reinforcing material receiving portion from slipping out of the reinforcing material receiving portion.

[0047] In Feature 4, the side support portions can be reinforced by plate-shaped reinforcing members. By arranging the plate-shaped reinforcing members so that the thickness direction of the plate-shaped reinforcing members coincides with the width direction of the side support portions, it is possible to reinforce the side support portions while ensuring a sufficient gap between the cushions.

[0048] In feature 5, since the plate-shaped reinforcing member is press-fitted into the reinforcing member receiving portion, it is possible to prevent the plate-shaped reinforcing member from coming out of the reinforcing member receiving portion.

[0049] In feature 6, since the plate-like reinforcing member is a pressed felt, it is possible to reinforce the side support portion while ensuring the cushioning properties of the side support portion.

[0050] In the seventh feature, the plate-shaped reinforcing member can be prevented from coming out of the reinforcing member receiving portion by the retaining projection.

[0051] Although the present specification and drawings disclose specific examples of the technology included in the scope of the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and variations of the specific examples, and also includes parts of the specific examples taken out alone. [Explanation of symbols]

[0052] 10 seat pad 11 Seat pad body 20 Side support part 21 Back recess 22 Backside protrusion 23 Flange 24 Frame receiving section 25 Reinforcement member receiving portion 29 Stopper protrusion 30 Backing material 35 Pocket section 40 Plate-shaped reinforcing member 48 Tongue piece 50 molding die 51 Lower mold 52 Upper mold 60 medium size 61 Overhang 62 Proximal part 63 Plate-shaped protrusion 64 Molded protrusion 90 sheets 91 Seating area 92 Backrest

Claims

1. A seat pad in which the side edge portions of the seat pad protrude outward to form side support portions that support the seated person from the sides, The seat pad is provided with a reinforcing member receiving portion formed from the rear surface of the side support portion to the interior thereof, into which a plate-shaped reinforcing member is inserted.

2. A backing material covering the back surface of the side support portion is provided, 2. The seat pad according to claim 1, wherein the backing material is provided with a pocket portion that covers the inner surface of the reinforcing member receiving portion and receives the plate-shaped reinforcing member.

3. The seat pad according to claim 2, wherein the backing material is provided with a tongue piece that connects the opening edges of the pocket portion.

4. The seat pad according to claim 1 , wherein the plate-shaped reinforcing member is provided in the reinforcing member receiving portion.

5. The seat pad according to claim 4, wherein the plate-shaped reinforcing member is press-fitted into the reinforcing member receiving portion.

6. 5. The seat pad according to claim 4, wherein the plate-like reinforcing member is a press felt.

7. 2. The seat pad according to claim 1, further comprising a retaining protrusion that protrudes from the inner surface of the reinforcing member receiving portion or the back surface of the side support portion, and that can catch on the plate-shaped reinforcing member and keep the plate-shaped reinforcing member within the reinforcing member receiving portion.

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