Method for manufacturing seat pad

Abstract

To provide a method for manufacturing a seat pad capable of suppressing a crush of a flow path when manufacturing a seat pad.SOLUTION: A method for manufacturing a seat pad includes: a pad body forming step for forming a pad body made of resin foam where recesses are formed on a reverse surface; and a reinforcement body insertion step for inserting a reinforcement body whose compression rigidity in a pad thickness direction is greater than the pad body in the recesses of the pad body. The pad body partitions ventilation holes succeeding from bottom surface of the recesses to the surface of the pad body. The reinforcement body contacts the bottom surface of the recesses, supports the bottom surface from the pad reverse side, and partitions inside communication holes communicating with the ventilation holes.SELECTED DRAWING: Figure 5B

Description

[Technical Field]

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

[0002] Seat pads with ventilation channels formed therein have been known for some time. Patent Document 1 discloses a vehicle seat pad as one such type of seat pad. The vehicle seat pad described in Patent Document 1 includes an air distribution duct that is embedded and integrated into the pad body.

[0003] Patent Document 1 also describes a method for manufacturing a vehicle seat pad. In the method for manufacturing a vehicle seat pad described in Patent Document 1, an air distribution duct in which a flow path is formed is set in a foaming mold, and then foam molding of the pad main body is performed. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-100505 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the manufacturing method of a seat pad as described in Patent Document 1, when the raw resin is heated and foamed, the air distribution duct is also heated, and the raw resin in the process of foaming presses against the air distribution duct, which causes deformation of the air distribution duct and may partially crush the flow path formed in the air distribution duct.

[0006] An object of the present disclosure is to provide a method for manufacturing a seat pad that can suppress collapse of a flow path when manufacturing the seat pad. [Means for solving the problem]

[0007] A method for manufacturing a seat pad according to a first aspect of the present disclosure includes: (1) a pad body forming step of forming a pad body made of foamed resin having a recess formed on a rear surface thereof; a reinforcing body inserting step of inserting a reinforcing body into the recess of the pad body, the reinforcing body having a compressive rigidity greater than that of the pad body in the pad thickness direction, The pad body defines an air hole that extends from the bottom surface of the recess to the surface of the pad body, The method for manufacturing a seat pad includes the step of: the reinforcing body contacting the bottom surface of the recess to support the bottom surface from the back side of the pad; and defining a communication hole therein that communicates with the ventilation hole.

[0008] A method for manufacturing a seat pad according to one embodiment of the present disclosure includes: (2) the reinforcing body includes a peripheral wall portion that defines the communication hole, In the method for manufacturing a seat pad according to (1) above, in the reinforcing member inserting step, the peripheral wall portion is fitted into the recess so as to contact or be close to a side surface of the recess.

[0009] A method for manufacturing a seat pad according to one embodiment of the present disclosure includes: (3) the reinforcing body includes a top wall portion that closes an end of the peripheral wall portion on the pad front side, In the method for manufacturing a seat pad according to (1) or (2) above, the top wall defines a top wall hole as one end opening of the communication hole.

[0010] A method for manufacturing a seat pad according to one embodiment of the present disclosure includes: (4) the reinforcing body includes a bottom wall portion that closes an end portion of the peripheral wall portion on the back side of the pad, In the method for manufacturing a seat pad according to (3) above, the bottom wall defines a bottom wall hole as the other end opening of the communication hole.

[0011] A method for manufacturing a seat pad according to one embodiment of the present disclosure includes: (5) the reinforcing body includes a conduit portion that protrudes from the top wall portion toward the front side of the pad and defines a connection hole that communicates with the top wall hole, In the method for manufacturing a seat pad described in (3) or (4) above, in the reinforcing body insertion process, the conduit portion is inserted into the ventilation hole so that the connection hole connects the ventilation hole and the communication hole.

[0012] A method for manufacturing a seat pad according to one embodiment of the present disclosure includes: (6) This is a method for manufacturing a seat pad described in any one of (3) to (5) above, wherein the reinforcing body has a protrusion that protrudes from the top wall portion and can be fitted into a fitting recess provided on the back side of the pad of the pad main body.

[0013] A method for manufacturing a seat pad according to one embodiment of the present disclosure includes: (7) The method for manufacturing a seat pad described in any one of (1) to (6) above, wherein the shape of the portion of the reinforcing body that is inserted into the recess when viewed from the thickness direction of the pad is circular, oval, or polygonal. [Effects of the Invention]

[0014] According to the present disclosure, it is possible to provide a method for manufacturing a seat pad that can suppress collapse of the flow path when manufacturing the seat pad. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is an external perspective view showing a vehicle seat including a seat pad manufactured using a seat pad manufacturing method according to an embodiment of the present disclosure; [Figure 2] 2 is a plan view of the cushion pad shown in FIG. 1 as viewed from the front side of the pad. FIG. [Figure 3] FIG. 3 is a cross-sectional view taken along line II in FIG. 2. [Figure 4]1 is a flowchart illustrating an embodiment of a method for manufacturing a seat pad. [Figure 5A] 5 is a diagram showing an outline of the pad body forming step shown in FIG. 4. FIG. [Figure 5B] FIG. 5 is a diagram showing an outline of the reinforcing body inserting step shown in FIG. 4. [Figure 6] FIG. 4 is a perspective view of the reinforcing member shown in FIG. 3. [Figure 7] 7 is a diagram showing another example of the reinforcing member shown in FIG. 6. FIG. [Figure 8] 1. FIG. 4 is an enlarged view showing a modified example of the cushion pad shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, an embodiment of a method for manufacturing a seat pad according to the present disclosure will be described with reference to the drawings. In each drawing, the same components are designated by the same reference numerals.

[0017] First, a seat pad 1 will be described as an example of a seat pad manufactured using the manufacturing method for a seat pad according to the present disclosure.

[0018] Fig. 1 is an external perspective view showing a vehicle seat 100 as an example of a seat including a seat pad 1. As shown in Fig. 1, the vehicle seat 100 includes a seating portion 101 on which an occupant sits, and a backrest portion 102 that supports the back of the occupant.

[0019] As shown in Fig. 1, a vehicle seat 100 includes a seat pad 1 and a cover member 110 that covers the outer surface of the seat pad 1. The seat pad 1 includes a cushion pad 1a that is placed in a seating portion 101, and a back pad 1b that is placed in a backrest portion 102. The cover member 110 is made of a breathable material such as cloth or punched leather. In Fig. 1, the cover member 110 is shown by a solid line, and for ease of explanation, the seat pad 1 that is covered by the cover member 110 is shown by a dashed line.

[0020] In this specification, the directions "up," "down," "left," "right," "front," and "rear" are simply referred to as "up," "down," "left," "right," "front," and "rear," respectively, in a front view of the vehicle seat 100, which is a perspective from the seating portion 101 side facing the backrest portion 102. Also, in this specification, the thickness direction of the seat pad 1 is simply referred to as the "pad thickness direction A." Specifically, in the case of the cushion pad 1a, the pad thickness direction A refers to the approximately vertical direction, which is both the direction from the upper surface of the cushion pad 1a to the lower surface and the direction from the lower surface of the cushion pad 1a to the upper surface. Also, in the case of the back pad 1b, the pad thickness direction A refers to the approximately longitudinal direction, which is both the direction from the front surface of the back pad 1b to the rear surface and the direction from the rear surface of the back pad 1b to the front surface.

[0021] In this specification, in the pad thickness direction A, the side of the seat pad 1 on which a seated person is positioned is referred to as the "pad front side A1," and the side opposite the pad front side A1 is referred to as the "pad back side A2." That is, in the case of the cushion pad 1a, the pad front side A1 points approximately upward, and the pad back side A2 points approximately downward. In the case of the back pad 1b, the pad front side A1 points approximately forward, and the pad back side A2 points approximately backward. Furthermore, in this specification, for each element, the surface of the pad front side A1 is simply referred to as the "front surface," and the surface of the pad back side A2 is simply referred to as the "back surface." For example, in the case of the cushion pad 1a, the front surface 5a (see Figures 2 and 3) refers to the upper surface, and the back surface 5b (see Figure 3) refers to the lower surface.

[0022] In the following, the cushion pad 1a of the seat pad 1 will be mainly described.

[0023] Fig. 2 is a plan view of the cushion pad 1a as seen from the pad front side A1. As shown in Figs. 1 and 2, the cushion pad 1a has a main pad portion 10 configured to receive the buttocks and thighs of a seated person, a pair of side pad portions 11 located on both the left and right sides of the main pad portion 10, and a back pad facing portion 12 located behind the main pad portion 10 and configured to face the back pad 1b in the up-down direction. The main pad portion 10 has a sub-buttocks portion 10a configured to receive the buttocks of a seated person, and a sub-thigh portion 10b located in front of the sub-buttocks portion 10a and configured to receive the thighs of the seated person.

[0024] As shown in FIG. 2, the cushion pad 1a defines an air flow path 80 that opens to the surface 5a. As will be described in detail later, the air flow path 80 includes an air vent 25 (see FIG. 3) in the pad main body 20 and a communication hole 55 (see FIG. 3) in the reinforcing body 40. In the vehicle seat 100 of this embodiment, air can be sucked from the surface 5a of the cushion pad 1a through the air flow path 80 of the cushion pad 1a by a driving device such as a pump connected to the cushion pad 1a. This allows the occupant of the vehicle seat 100 to feel cool and cool. However, the vehicle seat 100 may be configured to be able to exhaust air from the surface 5a of the cushion pad 1a through the air flow path 80 of the cushion pad 1a. Furthermore, the vehicle seat 100 may be configured to be able to selectively suction and exhaust air from the surface 5a of the cushion pad 1a through the air flow path 80 of the cushion pad 1a.

[0025] As described above, the cover member 110 of the vehicle seat 100 is made of a breathable material. Therefore, in the vehicle seat 100 of this embodiment, the above-mentioned suction and / or discharge of air is performed via the cover member 110. However, the vehicle seat 100 may be configured so that the above-mentioned suction and / or discharge of air is performed without using the cover member 110.

[0026] As shown in Fig. 2, the cushion pad 1a of this embodiment defines a plurality of air flow paths 80. Specifically, the cushion pad 1a of this embodiment defines four air flow paths 80. In this embodiment, all four air flow paths 80 are arranged in the lower thigh portion 10b of the cushion pad 1a. Also, in this embodiment, the four air flow paths 80 are arranged in the vicinity of the four corners of the rectangular lower thigh portion 10b when viewed from the pad front side A1. However, the number and arrangement of the air flow paths 80 provided in the cushion pad 1a are not limited to the configuration of this embodiment.

[0027] Fig. 3 is a cross-sectional view taken along line II in Fig. 2. Specifically, Fig. 3 shows a cross section parallel to the pad thickness direction A and passing through the air flow path 80. As shown in Fig. 3, the cushion pad 1a includes a pad main body 20 and a reinforcing body 40. In this embodiment, the surface 5a of the cushion pad 1a is formed by the surface 20a of the pad main body 20. Furthermore, the back surface 5b of the cushion pad 1a is formed by the back surface 20b of the pad main body 20 and the back surface 71a of the bottom wall portion 71 serving as the back surface of the reinforcing body 40.

[0028] As shown in Fig. 3, a recess 21 recessed toward the pad front side A1 is formed on the back surface 20b of the pad main body 20. A reinforcing body 40 is inserted into this recess 21. The pad main body 20 defines an air vent 25 that continues from the bottom surface 21a of this recess 21 to the front surface 20a of the pad main body 20. The reinforcing body 40 defines a communication hole 55 therein that communicates with the air vent 25 of the pad main body 20. In other words, the air flow path 80 of the cushion pad 1a is configured to include the air vent 25 of the pad main body 20 and the communication hole 55 of the reinforcing body 40.

[0029] The pad body 20 is made of foamed resin. This foamed resin is formed by foaming a resin. Examples of the resin include polyurethane. As the polyurethane, soft polyurethane is preferable. However, the type of resin that forms the foamed resin of the pad body 20 is not particularly limited.

[0030] The compressive rigidity of the reinforcing body 40 in the pad thickness direction A is greater than the compressive rigidity of the pad main body 20 in the pad thickness direction A. The reinforcing body 40 comes into contact with the bottom surface 21a of the recess 21 of the pad main body 20 and supports this bottom surface 21a from the pad back side A2. By providing such a reinforcing body 40, excessive deformation of the seat pad 1 due to the weight of a seated person can be suppressed. As a result, the air flow path 80 of the seat pad 1 can be prevented from being crushed and blocked due to the weight of a seated person.

[0031] The reinforcing body 40 may be made of a fabric material such as hard felt, a metal such as stainless steel, a hard resin, etc. However, the material constituting the reinforcing body 40 is not particularly limited as long as the compressive rigidity of the reinforcing body 40 in the pad thickness direction A is greater than the compressive rigidity of the pad main body 20 in the pad thickness direction A.

[0032] Next, an example of a method for manufacturing the above-mentioned seat pad 1 will be described as an embodiment of the method for manufacturing a seat pad according to the present disclosure. Fig. 4 is a flowchart showing an example of the method for manufacturing the seat pad 1. As shown in Fig. 4, the method for manufacturing the seat pad 1 of this embodiment includes a pad main body forming step S1 and a reinforcing body inserting step S2.

[0033] <Pad body forming process S1> 5A is a diagram showing an overview of the pad body forming step S1. As shown in FIG. 5A, in the pad body forming step S1, the pad body 20 is formed. Specifically, in the pad body forming step S1 of this embodiment, raw material resin is supplied into a foaming mold and then heated. This causes the raw material resin to foam, and the pad body 20 is foam-molded. However, the pad body forming step S1 is not limited to the configuration of this embodiment, and may be performed by cutting a foam body, or may be performed by combining foam molding and cutting.

[0034] <Reinforcing body insertion step S2> 5B is a diagram showing an outline of the reinforcing body inserting step S2. As shown in FIG. 5B, in the reinforcing body inserting step S2, the reinforcing body 40 is inserted into the recess 21 of the pad main body 20 formed in the pad main body forming step S1. This allows the cushion pad 1a (see FIG. 3) as the seat pad 1 described above to be manufactured.

[0035] Here, as described in Patent Document 1, when foam-molding the pad main body 20 with the reinforcement body 40 set in a foaming mold, the reinforcement body 40 is heated when the raw resin is heated and foamed, and the reinforcement body 40 is pressed by the raw resin during foaming, which may cause deformation of the reinforcement body 40. If the reinforcement body 40 is deformed, the communication hole 55 of the reinforcement body 40, which is part of the air flow path 80, may be crushed. In contrast, in the manufacturing method of the seat pad of this embodiment, the reinforcement body 40 is inserted into the recess 21 of the pad main body 20 after the pad main body 20 is formed, so the above-mentioned heating and pressing of the reinforcement body 40 are less likely to occur. In other words, the manufacturing method of the seat pad 1 of this embodiment can suppress deformation of the reinforcement body 40 and suppress collapse of the air flow path 80.

[0036] Furthermore, as described in Patent Document 1, when the pad main body 20 is foam-molded with the reinforcing body 40 set in a foaming mold, there is a risk that the raw resin may infiltrate into the reinforcing body 40 during the foam-molding process. The infiltration of the raw resin into the reinforcing body 40 may result in a decrease in the density of the pad main body 20 and a decrease in the cross-sectional area of ​​the communicating holes 55 of the reinforcing body 40. The decrease in the density of the pad main body 20 reduces the cushioning properties of the seat pad 1. The decrease in the cross-sectional area of ​​the communicating holes 55 reduces the ventilation efficiency of the seat pad 1. In contrast, in the manufacturing method of the seat pad 1 of this embodiment, the reinforcing body 40 is inserted into the recess 21 of the pad main body 20 after the pad main body 20 is formed, so that the raw resin is less likely to infiltrate into the reinforcing body 40 during foaming. In other words, the manufacturing method of the seat pad 1 of this embodiment can prevent a decrease in the cushioning properties of the seat pad 1 and a decrease in the ventilation efficiency of the seat pad 1.

[0037] Next, the manufacturing method of the seat pad 1 of this embodiment will be described in further detail.

[0038] The recess 21 of the pad main body 20 of this embodiment has a bottom surface 21a extending perpendicular to the pad thickness direction A and side surfaces 21b extending parallel to the pad thickness direction A. The recess 21 of the pad main body 20 of this embodiment has a rectangular cross section perpendicular to the pad thickness direction A. Specifically, the recess 21 of the pad main body 20 of this embodiment has four side surfaces 21a. These four side surfaces 21a form the respective sides of the rectangle in a cross section perpendicular to the pad thickness direction A.

[0039] 6 is a perspective view of the reinforcing body 40 of this embodiment. As shown in FIGS. 3, 5B, and 6, the reinforcing body 40 of this embodiment includes a peripheral wall portion 51, a top wall portion 61, and a bottom wall portion 71.

[0040] The peripheral wall portion 51 of this embodiment has side surfaces 51a extending parallel to the pad thickness direction A. The peripheral wall portion 51 of this embodiment has a rectangular shape when viewed from the pad thickness direction A. Specifically, the peripheral wall portion 51 of this embodiment has four side surfaces 51a. These four side surfaces 51a form the respective sides of the rectangle when viewed from the pad thickness direction A.

[0041] In the reinforcing body insertion step S2 of this embodiment, the peripheral wall portion 51 of the reinforcing body 40 is fitted into the recess 21 of the pad main body 20 so as to contact or be close to the side surface 21b of the recess 21 of the pad main body 20. In other words, when the reinforcing body 40 is inserted into the recess 21 of the pad main body 20, the side surface 51a of the peripheral wall portion 51 of the reinforcing body 40 is in contact with or be close to the side surface 21b of the recess 21 of the pad main body 20. By doing so, when the reinforcing body 40 is inserted into the recess 21 of the pad main body 20, it is possible to prevent misalignment between the ventilation holes 25 of the pad main body 20 and the communication holes 55 of the reinforcing body 40 in a direction perpendicular to the pad thickness direction A. This prevents a decrease in the cross-sectional area of ​​the ventilation flow path 80 of the seat pad 1 at the position where the ventilation holes 25 and the communication holes 55 are connected, thereby preventing a decrease in the ventilation efficiency of the seat pad 1. In addition, "the peripheral wall portion 51 is close to the side surface 21b of the recess 21 of the pad main body 20" means that the peripheral wall portion 51 is not in direct contact with the side surface 21b of the recess 21, but is arranged between the peripheral wall portion 51 and the side surface 21b of the recess 21 via a gap of a predetermined thickness or less.

[0042] The peripheral wall portion 51 defines a communication hole 55. Specifically, the communication hole 55 is defined by the inner surface of the peripheral wall portion 51. The communication hole 55 in this embodiment is a through-hole that penetrates the reinforcing body 40 in the pad thickness direction A. The peripheral wall portion 51 in this embodiment defines only one communication hole 55. Therefore, in the cushion pad 1a of this embodiment, each of the four air flow paths 80 is configured to have a common communication hole 55.

[0043] The communication hole 55 of this embodiment has a rectangular shape when viewed from the pad thickness direction A. Therefore, the peripheral wall portion 51 of this embodiment has a square cylindrical shape.

[0044] The top wall portion 61 closes the end of the pad front side A1 of the peripheral wall portion 51. In the reinforcing body insertion step S2 of this embodiment, the reinforcing body 40 is inserted into the recess 21 of the pad body 20 so that the surface 61a of the top wall portion 61 contacts the bottom surface 21a of the recess 21 of the pad body 20. In this manner, the surface 61a of the top wall portion 61 can support the bottom surface 21a of the recess 21 of the pad body 20. This makes it possible to further prevent the seat pad 1 from being deformed by the weight of the seated person and the air flow path 80 from being crushed and blocked, as compared to a case in which the reinforcing body 40 does not have the top wall portion 61.

[0045] Before the reinforcing body insertion step S2 is performed, adhesive may be applied in advance to the surface 61a of the top wall portion 61. In this way, the pad main body 20 and the reinforcing body 40 can be bonded together in the reinforcing body insertion step S2, and the reinforcing body 40 can be fixed to the pad main body 20. This makes it possible to prevent the reinforcing body 40 from unintentionally falling off from the pad main body 20 when the seat pad 1 is transported after being manufactured.

[0046] The top wall portion 61 of this embodiment has a flat shape whose thickness direction coincides with the pad thickness direction A. The top wall portion 61 of this embodiment has a rectangular shape when viewed from the pad thickness direction A.

[0047] The top wall portion 61 defines a top wall hole 65 as one end opening of the communication hole 55. The top wall hole 65 is a through hole that penetrates the top wall portion 61 in the pad thickness direction A. The top wall portion 61 of this embodiment defines four top wall holes 65. Each of the four top wall holes 65 is connected to each of the four ventilation holes 25 of the pad main body 20. The number of top wall holes 65 formed in the top wall portion 61 is not particularly limited. For example, the top wall portion 61 may be configured to have only one large top wall hole 65 that is connected to the four ventilation holes 25 of the pad main body 20.

[0048] The bottom wall portion 71 closes the end of the pad back side A2 of the peripheral wall portion 51. The back surface 71a of the bottom wall portion 71 forms part of the back surface 5b of the cushion pad 1a. The back surface 71a of the bottom wall portion 71 in this embodiment is configured to smoothly connect with the back surface 20b of the pad main body 20 without forming a step. This can improve the unity between the pad main body 20 and the reinforcing body 40. The bottom wall portion 71 in this embodiment has a flat shape whose thickness direction is approximately the same as the pad thickness direction A. The bottom wall portion 71 in this embodiment has a rectangular shape when viewed from the pad thickness direction A.

[0049] The bottom wall portion 71 defines a bottom wall hole 75 as the other end opening of the communication hole 55. The bottom wall hole 75 is a through-hole that penetrates the bottom wall portion 71 in the pad thickness direction A. The bottom wall portion 71 of the present embodiment defines only one bottom wall hole 75. A driving device such as a pump is connected to the cushion pad 1a of the present embodiment using the bottom wall hole 75. Therefore, the number and arrangement of the bottom wall holes 75 may be changed as appropriate depending on the configuration of the driving device connected to the cushion pad 1a.

[0050] 6, the reinforcing body 40 of this embodiment has a rectangular parallelepiped outer shape formed by the peripheral wall portion 51, the top wall portion 61, and the bottom wall portion 71. However, the shape of the reinforcing body 40 is not limited to the configuration of this embodiment as long as it can support the bottom surface 21a of the recessed portion 21 of the pad main body 20 and defines the communication holes 55 that communicate with the air vents 25 of the pad main body 20.

[0051] When viewed from the pad thickness direction A, the shape of the portion of the reinforcing body 40 that is inserted into the recess 21 of the pad main body 20 is preferably circular (see FIG. 7(a)), oval (see FIG. 7(b)), or polygonal (see FIGS. 6 and 7(c)). By configuring the portion of the reinforcing body 40 that is inserted into the recess 21 of the pad main body 20 in this way to have a simple shape, it is easy to reduce the contact area of ​​the reinforcing body 40 with the pad main body 20 when inserting the reinforcing body 40 into the recess 21 of the pad main body 20. This makes it easier to insert the reinforcing body 40 into the recess 21 of the pad main body 20, and allows the reinforcing body insertion step S2 to be performed efficiently.

[0052] Furthermore, it is preferable that the reinforcing body 40 has a columnar outer shape. In this way, the reinforcing body 40 can be configured with a simple structure, and an increase in the manufacturing cost of the reinforcing body 40 can be suppressed.

[0053] FIG. 8 is an enlarged view showing a modified example of a cushion pad 1a serving as the seat pad 1. As shown in FIG. 8, the reinforcing member 40 may include a conduit 90 that protrudes from the top wall 61 toward the pad front side A1 and defines a connection hole 91 that communicates with the top wall hole 65. The connection hole 91 is a through-hole that penetrates the conduit 90 in the pad thickness direction A. In this case, in the reinforcing member insertion step S2, the conduit 90 is inserted into the ventilation hole 25 so that the connection hole 91 communicates the ventilation hole 25 with the communication hole 55. This prevents misalignment between the ventilation hole 25 of the pad main body 20 and the communication hole 55 of the reinforcing member 40 in the direction perpendicular to the pad thickness direction A. This prevents a reduction in the cross-sectional area of ​​the ventilation flow path 80 of the seat pad 1 at the position where the ventilation hole 25 connects with the communication hole 55, thereby preventing a decrease in the ventilation efficiency of the seat pad 1.

[0054] From the viewpoint of the comfort of sitting on seat pad 1, it is preferable that length L2 of conduit portion 90 in pad thickness direction A be shorter than length L1 of ventilation hole 25 of pad body 20 in pad thickness direction A. Specifically, the ratio of length L2 of conduit portion 90 to length L1 of ventilation hole 25 (i.e., L2 / L1) is preferably 0.25 or less, more preferably 0.125 or less, and even more preferably 0.1 or less. The shape of conduit portion 90 is not particularly limited and may be, for example, cylindrical, square tubular, etc.

[0055] The number of conduit portions 90 is not particularly limited, but in order to reliably prevent the above-mentioned misalignment from occurring, when a plurality of vent holes 25 are formed in pad body 20, it is preferable that a plurality of conduit portions 90 is also provided in reinforcing body 40. In the example shown in Fig. 8, reinforcing body 40 is provided with four conduit portions 90 corresponding to the four vent holes 25, respectively.

[0056] 8, the reinforcing body 40 may have a protrusion 95 protruding from the top wall portion 61 toward the pad front side A1. The pad main body 20 may have a fitting recess 32 that can fit with the protrusion 95. Specifically, the fitting recess 32 is a recess that is recessed from the bottom surface 21a of the recess 21 of the pad main body 20 toward the pad front side A1. In this case, in the reinforcing body insertion step S2, the protrusion 95 is fitted into the fitting recess 32. With the protrusion 95 fitted into the fitting recess 32, relative movement between the pad main body 20 and the reinforcing body 40 in a direction perpendicular to the pad thickness direction A is restricted. As a result, misalignment between the ventilation hole 25 of the pad main body 20 and the communication hole 55 of the reinforcing body 40 in a direction perpendicular to the pad thickness direction A can be suppressed. This makes it possible to prevent a reduction in the cross-sectional area of ​​the ventilation flow path 80 of the seat pad 1 at the position where the ventilation hole 25 and the communication hole 55 are connected, and to prevent a decrease in the ventilation efficiency of the seat pad 1.

[0057] Although the number and arrangement of the protrusions 95 are not particularly limited, it is preferable that the reinforcing body 40 include a plurality of protrusions 95 in order to reliably prevent the above-mentioned misalignment from occurring. In this case, the pad main body 20 may have mating recesses 32 formed therein corresponding to the number and arrangement of the protrusions 95. Furthermore, the shape of the protrusions 95 is not particularly limited and may be, for example, cylindrical or rectangular. The mating recesses 32 may have a shape corresponding to the shape of the protrusions 95. Furthermore, in order to prevent gaps from occurring between the pad main body 20 and the reinforcing body 40, it is preferable that the length of the protrusions 95 in the pad thickness direction A is smaller than the depth of the mating recesses 32 in the pad thickness direction A.

[0058] In the example shown in FIG. 8 , the reinforcing body 40 includes both the conduit portion 90 and the protrusion 95. However, the reinforcing body 40 may include only the conduit portion 90 without the protrusion 95. In this case, the pad main body 20 does not need to have a fitting recess 32. Conversely, the reinforcing body 40 may include only the protrusion 95 without the conduit portion 90. The pad main body 20 may have a fitting recess 32. However, by having the reinforcing body 40 include the conduit portion 90 and the protrusion 95 and having the pad main body 20 include the fitting recess 32, it is possible to more effectively prevent misalignment between the air vent 25 of the pad main body 20 and the communication hole 55 of the reinforcing body 40 in the direction perpendicular to the pad thickness direction A, compared to when the reinforcing body 40 includes only one of the conduit portion 90 and the protrusion 95.

[0059] In the above embodiment, the method for manufacturing the seat pad 1 has been mainly described with reference to the method for manufacturing the cushion pad 1a, but the method for manufacturing the seat pad 1 of this embodiment can be similarly applied to the back pad 1b.

[0060] The manufacturing method of the seat pad according to the present disclosure is not limited to the specific configurations shown in the above-described embodiments and modified examples, and various modifications, changes, and combinations are possible without departing from the scope of the claims. For example, in the above-described embodiment, an example was shown in which an external device such as a pump is connected to the bottom wall hole 75 of the bottom wall portion 71 of the reinforcement body 40, but a hole for connecting an external device such as a pump may be formed in the peripheral wall portion 51 of the reinforcement body 40. In this case, the bottom wall portion 71 does not need to have the bottom hole 75 formed therein. [Industrial Applicability]

[0061] The present disclosure relates to a method for manufacturing a seat pad. [Explanation of symbols]

[0062] 1: Seat pad 1a: Cushion pad 1b: Back pad 5a: Cushion pad surface 5b: Back of cushion pad 10: Main pad section 10a: Lower buttocks 10b: Lower thigh 11: Side pad section 12: Back pad facing part 20: Pad body 20a: Surface of the pad body 20b: Back of the pad body 21: Recess 21a: Bottom surface of the recess of the pad body 21b: Side of the recess of the pad body 25: Ventilation hole 32: Fitting recess 40: Reinforcement 51: Peripheral wall part 51a: Side of the peripheral wall 55:Communication hole 61: Ceiling wall 61a: Surface of the ceiling wall 65: Ceiling hole 71: Bottom wall 71a: Back surface of bottom wall 75:Bottom wall hole 80: Ventilation channel 90: Conduit part 91: Connection hole 95: Convex 100: Vehicle seats 101: Seating area 102: Backrest 110: Cover member A: Pad thickness direction A1: Pad front side A2: Back of the pad L1: Length of the ventilation hole L2: Length of the conduit S1: Pad body forming process S2: Reinforcement insertion process

Claims

1. a pad body forming step of forming a pad body made of foamed resin having a recess formed on a rear surface thereof; a reinforcing body inserting step of inserting a reinforcing body into the recess of the pad body, the reinforcing body having a compressive rigidity greater than that of the pad body in the pad thickness direction, The pad body defines an air hole that extends from the bottom surface of the recess to the surface of the pad body, A method for manufacturing a seat pad, wherein the reinforcing body contacts the bottom surface of the recess to support the bottom surface from the back side of the pad, and defines a communication hole therein that communicates with the air vent.

2. the reinforcing body includes a peripheral wall portion that defines the communication hole, The method for manufacturing a seat pad according to claim 1 , wherein in the reinforcing member inserting step, the peripheral wall portion is fitted into the recess so as to contact or be close to a side surface of the recess.

3. the reinforcing body includes a top wall portion that closes an end of the peripheral wall portion on the pad front side, The method for manufacturing a seat pad according to claim 1 or 2, wherein the top wall defines a top wall hole as one end opening of the communication hole.

4. the reinforcing body includes a bottom wall portion that closes an end portion of the peripheral wall portion on the back side of the pad, The method for manufacturing a seat pad according to claim 3 , wherein the bottom wall defines a bottom wall hole as the other end opening of the communication hole.

5. the reinforcing body includes a conduit portion that protrudes from the top wall portion toward the front side of the pad and defines a connection hole that communicates with the top wall hole, The method for manufacturing a seat pad according to claim 3 , wherein in the reinforcing member inserting step, the conduit portion is inserted into the vent hole so that the connection hole communicates with the vent hole and the communication hole.

6. The method for manufacturing a seat pad according to claim 3 , wherein the reinforcing member has a protrusion that protrudes from the top wall portion and is capable of being fitted into a fitting recess that is provided on the back side of the pad body.

7. 3. The method for manufacturing a seat pad according to claim 1, wherein the shape of the portion of the reinforcing body that is inserted into the recess when viewed from the thickness direction of the pad is circular, oval, or polygonal.

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