Seat pad and mold for molding seat pad

Abstract

To provide a seat pad and a mold for molding the seat pad that can appropriately suppress molding leakage from an outer peripheral edge of a backing material.SOLUTION: The seat pad includes a pad main body 10 made of a foam-molded body, a molded backing material 20 that is preformed into a surface shape along a pad back surface 12 of the pad main body 10 and is integrally molded with the pad main body 10 so as to be disposed along the pad back surface 12, and a bent portion 24 which, in a peripheral portion 22 extending along an outer peripheral edge 23 of the molded backing material 20, bends so as to protrude toward a seat front side from the outer peripheral edge 23 as a base point.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present invention relates to a seat pad and a molding die for the seat pad, and more particularly to a seat pad and a molding die for the seat pad that integrally molds a preformed backing material along the back surface of the pad. [Background technology]

[0002] Patent Document 1 discloses a molding die for foam molding a cushion pad. The molding die has an upper die and a lower die that form a cavity corresponding to the outer shape of the cushion pad by clamping. The molding surface of the upper die forms the back surface of the pad. The molding surface of the lower die forms the front surface of the pad. A back surface material is set in a superimposed state on the molding surface of the upper die. In this set state, urethane is injected into the cavity and foam molded. As a result, the back surface material is integrally molded so that it lines the back surface of the cushion pad. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-20449 Summary of the Invention [Problem to be solved by the invention]

[0004] If the backing material is molded integrally with the pad body as in the above document, there is a concern that urethane may leak from the gap between the outer edge of the backing material and the molding surface of the upper mold, degrading the appearance of the seat. Therefore, we provide a seat pad and a molding die for the seat pad that can appropriately prevent leakage from the outer edge of the backing material. [Means for solving the problem]

[0005] In order to solve the above problems, the seat pad and the mold for the seat pad of the present invention take the following measures.

[0006] The first aspect of the present invention is a seat pad comprising: a pad main body made of a foam molded body; a molded back surface material that is pre-formed into a surface shape that follows the back surface of the pad main body and is integrally molded with the pad main body so as to be provided along the back surface of the pad; and a bent portion that extends along the outer periphery of the molded back surface material and bends from the outer periphery as a base point so as to protrude toward the front side of the seat.

[0007] The pad body having the above-described configuration is foam-molded integrally with a molded backing material set in a mold. This molded backing material is set in an overlapping state so that the recesses on the back side of the sheet at the bent portions face the molding surface of the mold. Therefore, during molding, the bent portions are pressed against the mold by foaming pressure. Therefore, compared to a configuration in which the molded backing material has a flat shape without bent portions, the bent portions are pressed more strongly against the molding surface. This makes it possible to appropriately suppress molding leakage from the outer peripheral edge of the molded backing material.

[0008] The second aspect of the present invention is a seat pad according to the first aspect, wherein the bent portion is formed at a position offset inward in the in-plane direction from the outer peripheral edge so as to leave a gap between the outer peripheral edge and the bent portion. According to the above configuration, the molded back surface material has an extension extending between the outer peripheral edge and the bent portion. The extension makes it easier to press the area between the bent portion and the outer peripheral edge against the molding surface in a wide plane. This makes it easier to prevent molding defects.

[0009] A third aspect of the present invention is the seat pad according to the first or second aspect, wherein the bent portion extends endlessly around the entire peripheral edge of the molded backing material. With this configuration, molding defects can be suppressed along the entire peripheral edge of the molded backing material.

[0010] A fourth aspect of the present invention is a seat pad according to the first or second aspect of the present invention, wherein the molded back surface material has a duct portion that forms the inner peripheral wall of a concave ventilation passage formed on the back surface of the pad, and a seat portion that extends along the back surface of the pad in an area outside the ventilation passage, and the bent portion is formed on the seat portion. With this configuration, the seat portion is strongly pressed against the molding surface, thereby preventing molding leakage into the duct portion.

[0011] The fifth aspect of the present invention is a molding die according to the first or second aspect of the present invention, which includes a set mold having a molding surface on which the molded backing material is set in an overlapping state, a mating mold that is clamped to the set mold to form a cavity between the set mold and the molded backing material for foam molding the pad body, and a bank portion that protrudes from the molding surface and enters a recess on the back side of the sheet at the bent portion. With this configuration, even if the molding material leaks into the recess at the bent portion, the bank portion can block the leaked molding material. Therefore, the molding material can be prevented from crossing the bent portion and penetrating far into the interior.

[0012] The sixth aspect of the present invention is a molding die according to the fifth aspect of the present invention, which has an engaging portion that protrudes from the bank portion and is inserted into a through-hole formed at the tip of the bent portion by setting the molding backing material, thereby engaging with the bent portion so as to press the bent portion against the molding surface against the elastic force of the bent portion. This configuration allows the bent portion to be pressed more strongly against the molding surface, thereby more appropriately suppressing molding defects.

[0013] The seventh aspect of the present invention is a mold according to the fifth aspect of the present invention, wherein the bank portion is provided at a gap from the bent portion so as not to interfere with the bent portion in the initial state after the molded back surface material is set. If the bank portion interferes with the bent portion in the initial state, variations in fit may cause the bank portion to push up the bent portion, causing the peripheral portion of the molded back surface material to lift off the molding surface. However, the seventh aspect of the present invention allows the bank portion to be set in a state where the peripheral portion of the molded back surface material is properly overlapped with the molding surface without interfering with the bent portion. This more appropriately prevents molding defects. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a perspective view of a seat cushion according to a first embodiment. [Figure 2] FIG. 2 is an exploded perspective view of the main module. [Figure 3]FIG. 2 is a perspective view of the main pad as seen from below. [Figure 4] FIG. 10 is a perspective view seen from below, showing a state in which a flow path cover is removed. [Figure 5] This is an oblique view from below showing the duct material in an exploded state. [Figure 6] FIG. [Figure 7] FIG. [Figure 8] FIG. 8 is a cross-sectional view taken along line VIII-VIII in FIG. 7. [Figure 9] FIG. 9 is a cross-sectional view taken along line IX-IX in FIG. [Figure 10] FIG. 10 is an enlarged view of the X portion of FIG. 9. [Figure 11] FIG. [Figure 12] FIG. 12 is an enlarged view of part XII in FIG. [Figure 13] FIG. 10 is an enlarged view showing the duct material fixed with a set pin. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, an embodiment of the present invention will be described with reference to Figures 1 to 13. In the following description, when directions such as front, back, up, down, left, and right are indicated, they refer to the directions shown in the drawings. Furthermore, when the term "seat width direction" is used, it refers to the left and right direction of the seat cushion 1, which will be described later.

[0016] First Embodiment First, a seat cushion 1 (seat pad) according to a first embodiment of the present invention will be described. As shown in Fig. 1, the seat cushion 1 forms a seating portion of an automobile seat. The seat cushion 1 has a seat air conditioning function that actively ventilates the inside of the seat cushion 1.

[0017] As shown in FIG. 1, the seat cushion 1 has a main module 2 that forms a main portion of the top panel that supports the buttocks of a seated person from below, and a pair of side modules 3 that form a pair of left and right side portions of the top panel that support the buttocks of the seated person from both the left and right. The main module 2 and each side module 3 are configured to be separable from each other. The seat cushion 1 also has a cushion frame (not shown) that forms the framework. The main module 2 and each side module 3 are assembled to the cushion frame from above.

[0018] As shown in FIG. 1, the main module 2 has multiple air vents 4 that penetrate its interior in the thickness direction (vertical direction). Each air vent 4 is a major component for implementing the seat air conditioning function described above. The seat cushion 1 has a blower (not shown) located below the main module 2. The blower is connected to each air vent 4 via a flow path, sucking in air from each air vent 4 and discharging it below the seat cushion 1. This achieves seat air conditioning. Seat air conditioning can improve the comfort of the seat cushion 1 by actively removing heat from within the main module 2.

[0019] <Main Module 2> As shown in FIG. 2, the main module 2 has a frame-shaped main resin 2a that forms the base, a main pad 10 that is attached to the main resin 2a from above, and a main cover 2b that is placed on the main pad 10 from above. The main pad 10 is made of a foam molded body and elastically supports the buttocks of a seated person. The main cover 2b is fitted underneath the main pad 10 and engaged with the main resin 2a, thereby assembling the main pad 10 integrally with the main resin 2a. Furthermore, the top plate of the main cover 2b is hung and engaged in the hanging groove 14 of the main pad 10. As a result, the main cover 2b is stretched and in close contact with the main pad 10. Here, the main pad 10 corresponds to the "pad main body" of the present invention.

[0020] The main pad 10 has the above-mentioned air vents 4 opening from its pad surface 11. As shown in FIG. 4, the main pad 10 has concave ventilation passages 13 formed in its pad back surface 12. Each air vent 4 opens at various points in the ventilation passage 13. A planar flow path lid 30 is placed on the ventilation passage 13 from below, thereby closing the opening of the ventilation passage 13 to the back side of the sheet (see FIG. 3). The flow path lid 30 has an opening 31 opening from a part of it, and the above-mentioned opening 31 is connected to the blower. Therefore, air sucked in through each air vent 4 passes through the ventilation passage 13 and the opening 31 and is exhausted below the main pad 10.

[0021] As shown in Figures 4 and 5, the main pad 10 has a molded backing material 20 provided along the pad back surface 12. The molded backing material 20 is a molded nonwoven fabric press-formed into a predetermined shape and is a harder member than the main pad 10. The molded backing material 20 is provided along the pad back surface 12. The molded backing material 20 has a duct portion 21 that forms the inner peripheral wall of the ventilation passage 13 and a seat portion 22 that extends along the pad back surface 12 away from the ventilation passage 13. The provision of the hard molded backing material 20 increases the strength of the ventilation passage 13 and the surrounding area of ​​the pad back surface 12. Therefore, even when a seating load is applied to the main pad 10, the shape of the ventilation passage 13 can be maintained so that it is not crushed. This makes it less likely that the flow of air through the ventilation passage 13 will be obstructed, preventing a deterioration in the seat air-conditioning function.

[0022] 5 and 6, the bearing surface portion 22 of the molded back surface material 20 is formed so as to extend along the outer peripheral edge 23 of the molded back surface material 20. The bearing surface portion 22 is formed with a bent portion 24 that is bent so as to protrude toward the front side of the seat. The bent portion 24 extends endlessly around the entire peripheral edge of the molded back surface material 20. As shown in FIGS. 9 and 10, the bent portion 24 has a shape that is curved from the outer peripheral edge 23 as a base point toward the front side of the seat, forming a U-shaped cross section.

[0023] The molded back surface material 20 is formed integrally with the main pad 10 during foam molding, and is provided along the pad back surface 12. As shown in Fig. 11, the main pad 10 is formed by foam molding a molding material poured into a cavity 41 in a mold 40. When molding the main pad 10, the molded back surface material 20 is set in advance on the back molding surface 42a of an upper mold 42. In this way, the molded back surface material 20 is molded integrally with the main pad 10.

[0024] 12, the bent portion 24 of the molded back surface material 20 is set so that its recess faces the back molding surface 42a. This bent portion 24 is subjected to the foaming pressure of the molding material when the main pad 10 is molded. As a result, the bearing surface portion 22 around the bent portion 24 is pressed firmly against the back molding surface 42a. This makes it possible to prevent molding leakage from a gap between the outer peripheral edge 23 of the molded back surface material 20 and the back molding surface 42a.

[0025] <Main Pad 10> The components of the main pad 10 and the molding die 40 described above will be described in detail below. As shown in Fig. 7, each vent hole 4 is formed in the front part of the pad surface 11 of the main pad 10. Each vent hole 4 is formed so as to penetrate from the pad surface 11 to the molded back surface material 20. The main pad 10 has a concave hanging groove 14 that extends in the sheet width direction along the pad surface 11. The hanging groove 14 is provided in two places side by side in the front-rear direction.

[0026] <Molded back surface material 20> 4 and 5, the ventilation passage 13 is formed in the front part of the pad back surface 12 of the main pad 10. The molded back surface material 20 is a substantially rectangular member that is attached to the front part of the pad back surface 12. The duct portion 21 of the molded back surface material 20 is provided along the entire ventilation passage 13. The duct portion 21 has a bottom surface 21a at the end of the recess, side walls 21b that rise from the periphery of the bottom surface 21a, and multiple protruding portions 21c that protrude in steps from parts of the bottom surface 21a along the side walls 21b. The protruding portions 21c form the ventilation passage 13 so that it branches out and extends in roughly five directions from the center.

[0027] As shown in Figure 6, the bearing surface portion 22 of the molded back surface material 20 protrudes in a flange-like shape from the end of the side wall 21b outward in the in-plane direction. Therefore, the bearing surface portion 22 forms a peripheral portion that surrounds the duct portion 21 formed in the middle portion of the molded back surface material 20. The bearing surface portion 22 further increases the strength of the molded back surface material 20. The bent portion 24 of the molded back surface material 20 extends continuously along the outer peripheral edge 23. The bent portion 24 is formed only in the bearing surface portion 22 without extending to the duct portion 21. In other words, the bent portion 24 is not formed in the middle portion of the molded back surface material 20 but only in the peripheral portion.

[0028] As shown in Fig. 10, the bent portion 24 is formed at a position offset inward in the in-plane direction from the outer peripheral edge 23 of the molded back surface material 20 so as to leave a gap between the bent portion 24 and the outer peripheral edge 23. Therefore, the bearing surface portion 22 has an extension portion 22a extending along the pad back surface 12 between the bent portion 24 and the outer peripheral edge 23. Therefore, as shown in Fig. 12, the extension portion 22a is pressed widely against the back molding surface 42a in a planar manner during pad molding. This makes it easier to prevent molding leakage from the outer peripheral edge 23.

[0029] <Flow channel lid 30> As shown in Figures 3 and 4, the flow path lid 30 is a planar member extending along the front portion of the pad back surface 12. The opening 31 of the flow path lid 30 has an elliptical shape extending along the seat width direction. As shown in Figures 8 and 9, the flow path lid 30 has a protrusion 32 on its periphery that protrudes toward the front side of the seat. The protrusion 32 extends endlessly around the entire periphery of the flow path lid 30.

[0030] As shown in Fig. 10, the flow path lid 30 is assembled to the molded back surface material 20 from below. With this assembly, the convex portion 32 of the flow path lid 30 fits into the recess on the back side of the sheet at the bent portion 24. This makes it easy to position the flow path lid 30 relative to the molded back surface material 20. Furthermore, an adhesive 5 such as hot melt is poured into the recess at the bent portion 24, and the inserted convex portion 32 is adhered to the bent portion 24. This fixes the flow path lid 30 in an assembled state to the molded back surface material 20. By pouring the adhesive 5 into the recess at the bent portion 24, it is possible to prevent the adhesive 5 from leaking out from between the flow path lid 30 and the molded back surface material 20 when the flow path lid 30 is assembled.

[0031] <Mold 40> As shown in FIG. 11 , the molding die 40 has an upper die 42 and a lower die 43 made of metal that face each other vertically. The upper die 42 and the lower die 43 are separable from each other, and for example, the upper die 42 is configured to be movable in the vertical direction. When the upper die 42 and the lower die 43 are clamped together, a cavity 41 is formed between their molding surfaces 42a, 43a. The cavity 41 forms the outer peripheral shape of the main pad 10. The main pad 10 is molded by pouring a molding material such as liquid polyurethane into this cavity 41 and foam molding it. Here, the upper die 42 corresponds to the "set die" in this invention. The lower die 43 corresponds to the "mating die" in this invention.

[0032] The lower mold 43 has a front molding surface 43a formed on its upper surface and groove-forming protrusions 43b protruding from the front molding surface 43a. The front molding surface 43a forms the surface shape of the pad surface 11. Each groove-forming protrusion 43b forms the inner shape of each hanging groove 14.

[0033] The upper mold 42 has a rear molding surface 42a formed on its lower surface. The rear molding surface 42a forms the surface shape of the pad rear surface 12. The molded back surface material 20 is set in an overlapping state on the rear molding surface 42a before molding the main pad 10. The upper mold 42 also has a plurality of hole-forming protrusions 42b protruding from the rear molding surface 42a. Each hole-forming protrusion 42b is passed through each vent hole 4 of the molded back surface material 20 when the molded back surface material 20 is set. Each hole-forming protrusion 42b forms the inner wall shape of the vent hole 4 of the main pad 10. Here, the rear molding surface 42a corresponds to the "molding surface" in this invention.

[0034] As shown in Fig. 12, the upper mold 42 has a bank portion 42c protruding from the rear molding surface 42a. The bank portion 42c enters the recess of the bent portion 24 of the molded back surface material 20 when the molded back surface material 20 is set. The bank portion 42c forms a wall that blocks the molding material that enters the recess of the bent portion 24, even if molding leakage occurs from the outer peripheral edge 23 during pad molding. This prevents the molding material from passing over the bent portion 24 and entering the duct portion 21. The bank portion 42c is formed to enter the entire area of ​​the bent portion 24 in the extension direction.

[0035] Furthermore, the bank portion 42c is provided so as to leave a gap 45 between it and the bent portion 24. This prevents the bank portion 42c from interfering with the bent portion 24 when the molded back surface material 20 is set on the back molding surface 42a. This prevents the bank portion 42c from pressing the bent portion 24 due to variations in the fit of the molded back surface material 20, causing the bearing surface portion 22 to float above the back molding surface 42a. In other words, the molded back surface material 20 can be set with the bearing surface portion 22 properly overlapping the back molding surface 42a. As a result, molding leakage from the outer peripheral edge 23 can be appropriately suppressed.

[0036] As shown in FIG. 13, the upper mold 42 has set pins 44 for holding the set molded back surface material 20 against the back molding surface 42a. The set pins 44 have a shaft 44a attached so as to protrude from the tip of the bank portion 42c, and a retaining portion 44b formed at the tip of the shaft 44a and having a larger diameter than the shaft 44a. The shaft 44a is attached, for example, by screwing into a screw hole provided in the bank portion 42c. A plurality of set pins 44 are provided so as to protrude from various locations on the bank portion 42c. Each set pin 44 is provided, for example, at a position corresponding to one of the four corners of the molded back surface material 20. Here, the set pins 44 correspond to the "engagement portion" of the present invention.

[0037] 13, the molded back surface material 20 has a plurality of through holes 24a formed at the tip of the bent portion 24 in accordance with the positions of the set pins 44. Each through hole 24a is passed through a set pin 44 when the molded back surface material 20 is set. As a result, each through hole 24a passes over and is hooked onto the retaining portions 44b of each set pin 44 in the setting direction. This hooking prevents the molded back surface material 20 from coming off the set pins 44. This holds the molded back surface material 20 so that it does not fall off.

[0038] The bent portion 24 engaged with each set pin 44 is sandwiched between the rear molding surface 42a and the retaining portions 44b, generating a resilient force. The retaining portions 44b press the bent portion 24 against the rear molding surface 42a against this resilient force. This allows the seat portion 22 to be pressed more strongly against the rear molding surface 42a. Therefore, molding leakage from the outer peripheral edge 23 can be further suppressed.

[0039] <Method of manufacturing the main pad 10> The procedure for manufacturing the main pad 10 will be described below. First, the molded back surface material 20 is press-molded into a predetermined shape. The upper mold 42 and the lower mold 43 are not clamped together. First, the molded back surface material 20 is set on the back molding surface 42a of the upper mold 42 (see FIG. 11). This causes the bottom surface 21a and sidewall 21b of the duct portion 21 to overlap the back molding surface 42a. In addition, the hole-forming protrusions 42b are passed through the vent holes 4 formed in the duct portion 21. The seat portion 22 is placed on the back molding surface 42a so that the bent portion 24 is aligned with the bank portion 42c of the upper mold 42. This causes the bank portion 42c to fit into the recess in the bent portion 24 (see FIG. 12). In addition, the set pin 44 is passed through the through hole 24a of the bent portion 24 (see FIG. 13). As a result, the molded back surface material 20 is held in a state set on the upper mold 42.

[0040] Next, as shown in Fig. 11, the upper mold 42 and the lower mold 43 are clamped together. This forms a cavity 41 for molding the main pad 10. The hole-forming protrusions 42b of the upper mold 42 are abutted against the front molding surface 43a of the lower mold 43. The groove-forming protrusions 43b of the lower mold 43 are positioned so as to leave a gap between them and the back molding surface 42a of the upper mold 42.

[0041] Then, a molding material is poured into the cavity 41, and the main pad 10 is foam-molded. The front molding surface 43a forms the pad surface 11. The hole-forming protrusions 42b form the vent holes 4 penetrating the main pad 10. The groove-forming protrusions 43b form the hanging grooves 14. The back molding surface 42a forms the pad back surface 12, and the molded back surface material 20 is molded integrally with the pad back surface 12. During foam molding, as shown in FIG. 12, the bent portion 24 is pressed against the back molding surface 42a by foaming pressure. This appropriately prevents the molding material from entering through the gap between the outer peripheral edge 23 of the molded back surface material 20 and the back molding surface 42a. In this manner, the main pad 10 is molded. As shown in FIGS. 8 and 9, the duct portion 21 of the molded back surface material 20 forms the ventilation passage 13. As described above, a flow path cover 30 is attached to the molded main pad 10 from the back side of the sheet (see FIG. 10).

[0042] To summarize the above, the seat pad and the molding die for the seat pad according to the first embodiment have the following configurations: In the following, the reference numerals in parentheses correspond to the respective components shown in the above embodiment.

[0043] That is, the seat pad (1) has a pad main body (10) made of a foam molded body, a molded back surface material (20) that is molded in advance into a surface shape that follows the pad back surface (12) of the pad main body (10) and is molded integrally with the pad main body (10) so as to be provided along the pad back surface (12), and a bent portion (24) that bends from the outer peripheral edge (23) at a peripheral portion (22) that extends along the outer peripheral edge (23) of the molded back surface material (20) so as to protrude toward the seat surface side, starting from the outer peripheral edge (23).

[0044] The pad body (10) configured as described above is foam-molded integrally with the molded backing material (20) set in the mold (40). The molded backing material (20) is set in an overlapping state with the recesses on the back side of the sheet of the bent portions (24) facing the molding surface (42a) of the mold (40). Therefore, during molding, the bent portions (24) are pressed against the mold (40) by foaming pressure. Therefore, compared to a flat-shaped configuration in which the molded backing material (20) does not have the bent portions (24), the bent portions (24) are pressed more strongly against the molding surface (42a). This makes it possible to appropriately prevent molding leakage from the outer peripheral edge (23) of the molded backing material (20).

[0045] Furthermore, the bent portion (24) is formed at a position offset inward in the in-plane direction from the outer peripheral edge (23) so as to leave a gap between the bent portion (24) and the outer peripheral edge (23). According to the above configuration, the molded back surface material (20) has an extension portion (22a) extending between the outer peripheral edge (23) and the bent portion (24). The extension portion (22a) makes it easier to press the area between the bent portion (24) and the outer peripheral edge (23) against the molding surface (42a) in a wide plane. This makes it easier to prevent molding defects.

[0046] Furthermore, the bent portion 24 extends endlessly along the entire periphery of the molded lining material 20. According to the above configuration, molding defects can be suppressed along the entire periphery of the molded lining material 20.

[0047] The molded back surface material (20) has a duct portion (21) that forms the inner peripheral wall of a concave ventilation passage (13) formed in the pad back surface (12), and a seating surface portion (22) that extends along the pad back surface (12) in an area outside the ventilation passage (13), and the bent portion (24) is formed in the seating surface portion (22). According to the above configuration, the seating surface portion (22) is pressed strongly against the molding surface (42a), thereby preventing molding leakage into the duct portion (21).

[0048] The molding die (40) includes a setting die (42) having a molding surface (42a) on which the molded backing material (20) is set in an overlapping state, a mating die (43) that is clamped to the setting die (42) to form a cavity (41) between the molded backing material (20) and the mating die (43) for foam molding the pad body (10) between the molded backing material (20), and a bank portion (42c) that protrudes from the molding surface (42a) and enters the recess on the back side of the sheet at the bent portion (24). According to the above configuration, even if the molding material leaks into the recess at the bent portion (24), the bank portion (42c) can block the leaked molding material. Therefore, the molding material can be prevented from going beyond the bent portion (24) and penetrating far into the interior.

[0049] The forming mold 40 also has an engaging portion 44 that protrudes from the bank portion 42c and is inserted into a through-hole 24a formed at the tip of the bent portion 24 by setting the forming back surface material 20, thereby engaging with the bent portion 24 to press the bent portion 24 against the forming surface 42a against the elastic force of the bent portion 24. This configuration allows the bent portion 24 to be pressed more strongly against the forming surface 42a, thereby more appropriately preventing molding defects.

[0050] In addition, the forming mold (40) is configured such that the bank portion (42c) is positioned away from the bent portion (24) by a gap (45) so as not to interfere with the bent portion (24) in the initial state after the forming backing material (20) is set. If the bank portion (42c) were configured to interfere with the bent portion (24) in the initial state, variations in fit could cause the bank portion (42c) to push up the bent portion (24), causing the peripheral portion (22) of the forming backing material (20) to lift off the forming surface (42a). However, with the above configuration, the bank portion (42c) does not interfere with the bent portion (24), and the peripheral portion (22) of the forming backing material (20) can be set in a state where it is properly overlapped with the forming surface (42a). This more appropriately prevents molding defects.

[0051] <Other embodiments> Although the present invention has been described above using one embodiment, the present invention can be embodied in various forms other than the above embodiment.

[0052] 1. The seat pad can be applied to seat cushions as well as seat backs. The seat pad can be widely applied to seats used in various vehicles other than automobiles, such as trains, airplanes, ships, etc., in addition to automobile seats.

[0053] 2. The seat pad may not have a seat air conditioning function. Therefore, the pad body may not have a ventilation passage, and the molded backing material may not have a duct portion.

[0054] 3. The peripheral edge portion may not have an extension, i.e., the bent portion may be bent so as to protrude from the peripheral edge of the molded backing material toward the front side of the sheet without being offset inward from the peripheral edge. Multiple bent portions may be provided intermittently along the peripheral edge. Furthermore, the bent portion does not need to extend along the entire peripheral edge, and may be formed only in a portion along the peripheral edge.

[0055] 4. The forming mold may have a configuration in which the lower mold forms the surface shape of the back surface of the pad, and the lower mold may be a setting mold in which the forming back surface material is set. The forming mold may have no bank portion. The bank portion may be formed so as to fit closely to the recess of the bent portion without any gap.

[0056] 5. The number of set pins is not limited to four, but may be two, three, or five or more. The set pins may be provided in only one location instead of multiple locations. The set pins may be attached to the setting mold so as to pass through the through-holes in the molded back surface material after the molded back surface material is set. The mold may not have set pins, and the molded back surface material may be held in the setting mold by vacuum suction, magnets, or the like. [Explanation of symbols]

[0057] 1 seat cushion (seat pad) 2 Main Module 2a Main Resin 2b Main cover 3 Side Module 4 ventilation holes 5. Adhesive 10 Main pad (pad body) 11 Pad surface 12 Back of pad 13 Ventilation duct 14 Hanging groove 20 Molded backing material 21 Duct section 21a Bottom 21b Side wall 21c Overhang 22 Seat part (periphery) 22a Extension 23 Outer rim 24 Bending section 24a through hole 30 Channel cover 31 Opening 32 Convex part 40 mold 41 Cavity 42 Upper mold (set type) 42a Back side molding surface (molding surface) 42b Hole-forming protrusion 42c Bank 43 Lower die (counter die) 43a Front molding surface 43b Grooving protrusion 44 Set pin (engagement part) 44a Shaft 44b Retaining part 45 Gap

Claims

1. A seat pad, a pad body made of a foam molded body; a molded backing material that is molded in advance into a surface shape that conforms to the back surface of the pad body and is integrally molded with the pad body so as to be provided along the back surface of the pad; The seat pad has a bent portion that is bent so as to protrude toward the front side of the seat from the outer periphery of the molded back surface material at a peripheral portion extending along the outer periphery of the molded back surface material.

2. 2. The seat pad according to claim 1, The seat pad has a bent portion formed at a position offset inward in an in-plane direction from the outer peripheral edge so as to leave a gap between the bent portion and the outer peripheral edge.

3. The seat pad according to claim 1 or 2, The bent portion extends endlessly around the entire periphery of the molded backing material.

4. The seat pad according to claim 1 or 2, the molded back surface material has a duct portion that forms an inner peripheral wall of a concave ventilation passage formed on the back surface of the pad, and a seat portion that extends along an area of ​​the back surface of the pad that is outside the ventilation passage, The bent portion is formed in the seat pad.

5. A mold for molding the seat pad according to claim 1 or 2, a set mold having a molding surface on which the molded back surface material is set in an overlapping state; a mating mold that is clamped to the set mold to form a cavity between the molded backing material and the mating mold to foam-mold the pad body; a bank portion that protrudes from the forming surface and fits into a recess on the back side of the sheet at the bent portion.

6. The mold according to claim 5, A molding die having an engaging portion that protrudes from the bank portion and is passed through a through hole formed at the tip of the bent portion by setting the molding back surface material, thereby engaging with the bent portion so as to press the bent portion against the molding surface against the elastic force of the bent portion.

7. The mold according to claim 5, The forming die is provided with a gap between the bank portion and the bent portion so as not to interfere with the bent portion in the initial state after the forming back surface material is set.

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