Wire, seat pad and mold

Abstract

We provide wires, sheet pads, and molds that offer a wide range of applications. [Solution] The wire includes a straight first section, two second sections adjacent to the two ends of the first section and bending in the same direction, two third sections adjacent to the ends of the second sections and bending in the opposite direction to the bending of the second sections, and two fourth sections connected to the ends of the third sections and extending in a direction intersecting the plane containing the first and second sections, wherein the angle between the first and second sections is obtuse, and the angle between the second and third sections is obtuse. The seat pad has the wire embedded in it.

Description

Technical Field

[0001] The present invention relates to a wire embedded in a seat pad, a seat pad, and a molding die.

Background Art

[0002] A technique for fixing the skin covering the seat pad using a wire embedded in the seat pad is known. The prior art disclosed in Patent Document 1 has a wire that is substantially U-shaped in plan view, including two longitudinal linear portions with open ends and a transverse linear portion connecting the longitudinal linear portions. The longitudinal linear portion of the wire has the function of fixing the skin, and the transverse linear portion has the function of connecting and integrating the longitudinal linear portions.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the prior art, in order to reduce the number of parts and the man-hours for arranging the parts, there is a need for a technique to increase the functions of the transverse linear portion of the wire embedded in the seat pad and to expand the range of utilization of the wire.

[0005] The present invention has been made to meet this requirement, and an object thereof is to provide a wire, a seat pad, and a molding die with a wider range of utilization.

Means for Solving the Problems

[0006] A first embodiment for achieving this objective is a wire embedded in a seat pad, comprising: a straight first part; two second parts adjacent to the two ends of the first part and bending in the same direction to each other; two third parts adjacent to the ends of the second parts and bending in the opposite direction to the direction in which the second parts bend; and two fourth parts connected to the ends of the third parts and extending in a direction intersecting a plane containing the first and second parts, wherein the angle between the first and second parts is obtuse, and the angle between the second and third parts is obtuse.

[0007] In the second aspect, as in the first aspect, the second part descends from the first part towards the end of the second part, and the third part intersects with a straight line passing through the two ends of the second part and descends from the second part towards the end of the third part.

[0008] The third embodiment is a seat pad in which the wires of the first or second embodiment are embedded.

[0009] A fourth aspect is a mold comprising a first mold and a second mold, wherein a sheet pad is molded in a space created by placing the second mold over the first mold. The first mold includes a fixing portion for positioning the wire in the first or second aspect in the space, the fixing portion including a first limiting portion that restricts the displacement of the third portion in a direction along a straight line passing through two ends of the second portion, and a second limiting portion that restricts the displacement of the fourth portion in a direction rotating around the straight line.

[0010] A fifth aspect, in the fourth aspect, allows for displacement of the end of the second part in a direction that moves the second part closer to the first part when creating space and rotates around the first limiting part. [Effects of the Invention]

[0011] According to the present invention, since two fourth parts extend in a direction intersecting the plane containing the first and second parts of the wire, the fourth parts can be positioned near the surface of the seat pad in which the wire is embedded, and the first part can be positioned near the back surface of the seat pad. The angle between the first and second parts of the wire is obtuse, and the angle between the second and third parts is also obtuse. Therefore, when a force is applied to the first part that widens the angles between the first and second parts, and between the second and third parts, the second and third parts will bend, thereby reducing the bending of the first part. The first part can be given functions such as fixing the surface, thus expanding the range of applications for the wire. [Brief explanation of the drawing]

[0012] [Figure 1] (a) is a plan view of a seat pad in one embodiment, and (b) is a cross-sectional view of the seat pad along the line Ib-Ib in Figure 1(a). [Figure 2] (a) is a plan view of the wire, (b) is a front view of the wire, and (c) is a side view of the wire. [Figure 3] (a) is a cross-sectional view of the mold in the first embodiment, and (b) is a perspective view of the first mold. [Figure 4] (a) is a perspective view of the mold (first mold) in the second embodiment, (b) is a front view of the fixing part as seen from the direction of arrow IVb in Figure 4(a), and (c) is a front view of the fixing part in a modified example. [Figure 5] (a) is a perspective view of the mold (first mold) in the third embodiment, and (b) is a front view of the fixing part as seen from the direction of arrow Vb in Figure 5(a). [Modes for carrying out the invention]

[0013] Preferred embodiments of the present invention will be described below with reference to the drawings. Figure 1(a) is a plan view of the seat pad 10 in one embodiment. Figure 1(b) is a cross-sectional view of the seat pad 10 along the line Ib-Ib in Figure 1(a). The seat pad 10 is a pad for a seat in a vehicle such as an automobile. In this embodiment, the seat pad 10 is described using a back pad as an example, but it is not limited to this. Other uses of the seat pad include a cushion to support the user's buttocks, an armrest for a sofa or chair, and a footrest.

[0014] The seat pad 10 comprises an elastic body 11 made of a synthetic resin foam such as soft polyurethane foam, and a wire 12 embedded in the body 11. The seat pad 10 may have a reinforcing fabric (not shown) integrated over almost the entire back surface 13 of the body 11. The reinforcing fabric is interposed between the frame (not shown) and the back surface 13 of the body 11 to reinforce the body 11 and reduce abnormal noise caused by friction between the frame and the body 11. Examples of reinforcing fabrics include coarse blankets, felt, and nonwoven fabrics.

[0015] The main body 11 includes a central section 14 located in the center in the width direction, and side sections 15 located on both the left and right sides of the central section 14. The surface 16 of the main body 11 is provided with two vertical grooves 17 extending along the boundary between the central section 14 and the side sections 15, and horizontal grooves 18 connecting the vertical grooves 17. The seat pad 10 is covered with a surface material (not shown) made of woven fabric or leather, for decoration and user comfort. Part of the surface material is suspended in the vertical grooves 17 and horizontal grooves 18 and fixed to the surface 16 of the main body 11. The wire 12 is embedded in the main body 11 along the vertical grooves 17 and horizontal grooves 18. Part of the wire 12 is located near the back surface 13 of the main body 11.

[0016] Figure 2(a) is a plan view of wire 12, Figure 2(b) is a front view of wire 12 viewed from direction IIb, and Figure 2(c) is a side view of wire 12 viewed from direction IIc. Wire 12 is made of a metal wire such as hard steel wire, and is made by bending the wire at multiple points. The thickness of wire 12 is exemplified as 2mm-3mm.

[0017] Wire 12 includes a first portion 19 that includes a straight portion, second portions 21 that are respectively adjacent to two ends 20 of the first portion 19, two third portions 23 that are respectively adjacent to ends 22 of the second portions 21, and two fourth portions 25 that are respectively connected to ends 24 of the third portions 23. The two fourth portions 25 extend in a direction intersecting the plane 26 that includes the first portion 19 and the second portions 21, and extend in the same direction with respect to the plane 26. When arranging the first portion 19, the second portions 21, the third portions 23, and the fourth portions 25 in descending order of length, it is the first portion 19, the fourth portions 25, the second portions 21, and the third portions 23. In the present embodiment, the first portion 19 is linear over its entire length.

[0018] Wire 12 is symmetric with respect to a plane (symmetric plane) that is perpendicular to the first portion 19 and includes the midpoint of the first portion 19. The plan view (see FIG. 2(a)) is a view of wire 12 seen at right angles to the horizontal plane when wire 12 is placed on the horizontal plane such that the angle formed by the horizontal plane and the plane 26 is 57°, and the front view (see FIG. 2(b)) is a view of wire 12 placed on the horizontal plane seen parallel to the horizontal plane.

[0019] In the front view (see FIG. 2(b)), the second portion 21 is bent (valley fold) in the same direction as the first portion 19, and the third portion 23 is bent in a direction opposite to the direction in which the second portion 21 is bent (mountain fold). The angle θ1 formed by the first portion 19 and the second portion 21 in the front view is an obtuse angle, and θ1 is preferably 130 - 165°. The angle θ2 formed by the second portion 21 and the third portion 23 in the front view is an obtuse angle, and θ2 is preferably 130 - 170°. The angle θ3 formed by the straight line 27 passing through the two ends 22 of the second portion 21 and the third portion 23 in the front view is exemplified as 165 - 180°.

[0020] The angle θ4 formed by the first portion 19 and the second portion 21 in the plan view (see FIG. 2(a)) is exemplified as 130 - 180°. The angle θ5 formed by the second portion 21 and the third portion 23 in the plan view is exemplified as 130 - 180°. The angle θ6 formed by the straight line 27 and the third portion 23 in the plan view is exemplified as 150 - 180°. The angle θ7 formed by the second portion 21 and the fourth portion 25 in the side view (see FIG. 2(c)) is exemplified as 90 - 130°.

[0021] The wire 12 is embedded in the main body 11 (see Fig. 1(a)) by insert molding. The first part 19, the second part 21, and the third part 23 of the wire 12 are arranged along the lateral groove 18 of the main body 11, and the fourth part 25 is arranged along the vertical groove 17.

[0022] Fig. 3(a) is a cross-sectional view of the mold 30 in the first embodiment. The mold 30 is a mold for insert molding of the wire 12, and includes a first mold (lower mold) 31 and a second mold 32 that covers the first mold 31 and creates a space (cavity) 33 between the first mold 31 and the second mold 32. The second mold 32 may include a plurality of molds such as an upper mold and a core mold integrated together. The first mold 31 and the second mold 32 are rotatably connected via a hinge (not shown), and the second mold 32 opens and closes with respect to the first mold 31. The hinge connecting the first mold 31 and the second mold 32 is joined near the portion that molds the lower end portion (lower part of Fig. 1(a)) of the main body 11 among the first mold 31 and the second mold 32.

[0023] The wire 12 is arranged in the space 33 by the fixing portion 34 provided on the first mold 31. With the second mold 32 open, the wire 12 is arranged on the first mold 31, a reinforcing cloth (not shown) is arranged on the second mold 32, and after injecting the raw material of the main body 11 (see Fig. 1(b)) into the first mold 31, the second mold 32 is closed, and the raw material is foamed and cured in the space 33, thereby obtaining the sheet pad 10 in which the main body 11, the wire 12, and the reinforcing cloth are integrated. The surface 16 of the main body 11 is molded by the first mold 31, and the back surface 13 of the main body 11 is molded by the second mold 32.

[0024] Fig. 3(b) is a perspective view of the first mold 31. Fig. 3(b) shows the vicinity of the fixing portion 34 of the first mold 31, and other illustrations are omitted. The fixing portion 34 includes a table 35 on which the wire 12 is placed, a protrusion 37 provided on the top surface 36 of the table 35, and a fixing portion 38 for fixing the wire 12 to the top surface 36. The fixing portion 34 further includes a table 39 arranged at a distance from the table 35 and a fixing portion 40 for fixing the wire 12 to the top surface of the table 39.

[0025] The raised portion 41 is a groove for creating the longitudinal groove 17 of the sheet pad 10 (see Figure 1(a)) and connects the bases 35 and 39. Since there are two longitudinal grooves 17 in the sheet pad 10, there is another set of bases 35, 39 and raised portion 41 in the first type 31, but the illustration of the other set of bases 35, 39 and raised portion 41 is omitted in Figure 3(b). In this embodiment, the material of the wire 12 is a ferromagnetic material, and the fixing portions 38 and 40 are magnets.

[0026] When the fourth portion 25 of the wire 12 is placed on the bases 35 and 39, the fixing portions 38 and 40 attract the fourth portion 25. The projection 37 is positioned in the corner formed by the third portion 23 and the fourth portion 25 of the wire 12. Since the height of the projection 37 is greater than the thickness of the wire 12, the projection 37 restricts the movement of the third portion 23 toward the base 39 of the wire 12 to which the fourth portion 25 is fixed by the fixing portions 38 and 40, and restricts the movement of the fourth portion 25 toward the other set of bases 35 and 39 and the raised portion 41. In this embodiment, the fourth portion 25 of the wire 12 rests on the top surface 36, but the base 35 is constructed so that the third portion 23 is not above the top surface 36.

[0027] As shown in Figure 3(a), when the second type 32 is closed, the first part 19 of the wire 12 is positioned near the second type 32. Due to variations in the bending angle of the wire 12, the height of the first part 19 relative to the third part 23 of the wire 12 may be large, and when the second type 32 is closed, the second type 32 rotates around the hinge (not shown) and hits the first part 19. When this happens, the first part 19 is pushed diagonally downward (upper left in Figure 3(b)) by the second type 32, but the third part 23 and the fourth part 25 catch on the projection 37 (part of the first limiting part), preventing the fourth part 25, which is along the raised part 41, from being displaced. In addition, the fixing part 38 (part of the second limiting part) to which the fourth part 25 is fixed restricts the displacement of the fourth part 25 in the direction of rotation around the straight line 27, preventing the fourth part 25 from lifting off the base 35. Since the fourth part 25 is fixed to the fixing part 40 (part of the second limiting part) of the base 39, which is positioned at a distance from the base 35, the lifting of the fourth part 25 from the base 35 can be further reduced.

[0028] When the first part 19 of the wire 12 is pressed by the second mold 32, and a downward force is applied to the first part 19, the second part 21, and the third part 23, the displacement of the third part 23 in the direction in which the straight line 27 extends on both sides is restricted because the fourth part 25 is attracted to the fixing part 38 (part of the first limiting part). Since the angle θ1 between the first part 19 and the second part 21 (see Figure 2(b)) and the angle θ2 between the second part 21 and the third part 23 are obtuse angles, the downward force applied to the first part 19 deforms angles θ1 and θ2, reducing the deflection of the first part 19, and causing the first part 19 to displace almost parallel. As a result, the distance between the back surface 13 of the main body 11 of the seat pad 10 (see Figure 1(b)) and the first part 19 remains almost constant along the entire length of the first part 19. This makes it easier to position parts such as hog rings that connect the cover (not shown) placed over the seat pad 10 to the first part 19 on the back surface 13 of the main body 11, or to fix the frame (not shown) to the first part 19 on the back surface 13 of the main body 11. Since the first part 19 of the wire 12 can be used to fix the cover or frame, the range of applications for the wire 12 can be expanded.

[0029] Since the base 35 is constructed so that the third part 23 of the wire 12 is detached from the top surface 36, when the first part 19 is pushed by the second type 32 and a downward force is applied to the first part 19, the second part 21, and the third part 23, the third part 23 rotates downward around the point of contact between the fourth part 25, which is fixed to the top surface 36, and the top surface 36. The base 35 does not hinder the rotation of the third part 23, and the base 35 allows the displacement of the end 22 of the second part 21 (see Figure 2(b)), so the deflection of the first part 19 can be further reduced.

[0030] A second embodiment will be described with reference to Figure 4. In the first embodiment, a mold 30 (first mold 31) was described in which a base 35 is made so that the third part 23 of the wire 12 is detached from the top surface 36. In the second embodiment, a first mold 50 will be described in which a base 52 is made so that the end 24 of the third part 23 of the wire 12 rests on the top surface 53. In the second embodiment, parts that are the same as those described in the first embodiment are denoted by the same reference numerals as in the first embodiment, and their descriptions are omitted below.

[0031] Figure 4(a) is a perspective view of the first type 50 in the second embodiment. Figure 4(a) shows the vicinity of the fixing part 51 of the first type 50, and other parts are omitted from the illustration. The fixing part 51 includes a base 52 on which the wire 12 rests, a projection 37 provided on the top surface 53 of the base 52, and a fixing part 38 for fixing the wire 12 to the top surface 53. The fixing part 51 further includes a base 39 positioned at a distance from the base 52, and a fixing part 40 for fixing the wire 12 to the top surface of the base 39. In this embodiment, the base 52 is made so that the third part 23 and the fourth part 25 of the wire 12 rest on the top surface 53.

[0032] Figure 4(b) is a front view of the fixing part 51 as seen from the direction of arrow IVb in Figure 4(a). The end 24 of the third part 23 of the wire 12 rests on the top surface 53 of the base 52 of the fixing part 51. The second part 21 of the wire 12 descends from the first part 19 as it approaches the end 22 of the second part 21 (see Figure 2(b)), and the third part 23 intersects with the straight line 27 and descends from the second part 21 as it approaches the end 24 of the third part 23. An example of the angle θ8 between the top surface 53 of the base 52 and the third part 23 of the wire 12 is 5-20°.

[0033] Because there is an angle θ8 between the top surface 53 and the third part 23, when the first part 19 is pressed against the second type 32 (see Figure 3(a)) and a downward force is applied to the first part 19, the second part 21, and the third part 23, the third part 23 rotates in the direction of arrow D around the point of contact between the end 24 of the third part 23, which rests on the top surface 53, and the top surface 53. Since the base 52 allows displacement of the end 22 of the second part 21 (see Figure 2(b)), the deflection of the first part 19 can be further reduced.

[0034] Figure 4(c) is a front view of the fixing part 54 in a modified example. The fixing part 54 includes a base 52 on which the wire 12 rests, a projection 37 provided on the top surface 53 of the base 52, and a hook-shaped fixing part 55 connected to the projection 37. The fixing part 55 (part of the second limiting part) is positioned on the fourth part 25 of the wire 12, whose end 24 of the third part 23 rests on the top surface 53. Similar to the fixing part 38, the fixing part 55 limits the displacement of the fourth part 25 in the direction of rotation around the straight line 27, preventing the fourth part 25 from lifting off the base 35. If the fixing part 55 is provided on the base 52, the fixing part 38 may be omitted.

[0035] A third embodiment will be described with reference to Figure 5. In the second embodiment, a case was described in which the wire 12 is bent so that the third part 23 rises from the end 24 of the third part 23 and the second part 21 rises from the end 22 of the second part 21 (see Figure 2(b)). In the third embodiment, a first type 60 having a fixing part 61 in which a wire 64 is positioned at the same height as the end 24 of the third part 23 and the end 22 of the second part 21 will be described. In the third embodiment, parts that are the same as those described in the first embodiment are denoted by the same reference numerals as in the first embodiment and their descriptions are omitted below.

[0036] Figure 5(a) is a perspective view of the first type 60 in the third embodiment. Figure 5(a) shows the vicinity of the fixing part 61 of the first type 60, and other parts are omitted from the illustration. The fixing part 61 includes a base 62 on which the wire 64 rests, a projection 37 provided on the top surface 63 of the base 62, and a fixing part 38 for fixing the wire 12 to the top surface 63. The fixing part 61 further includes a base 39 positioned at a distance from the base 62, and a fixing part 40 for fixing the wire 64 to the top surface of the base 39. In this embodiment, the base 62 is made so that the third part 23 and the fourth part 25 of the wire 64 rest on the top surface 63.

[0037] Figure 5(b) is a front view of the fixing part 61 as seen from the direction of arrow Vb in Figure 5(a). The end 24 of the third part 23 of the wire 64 rests on the top surface 63 of the base 62 of the fixing part 61. The top surface 63 slopes downward in the direction in which the third part 23 and the second part 21 of the wire 64 extend. An example of the angle θ9 between the top surface 63 of the base 62 and the third part 23 of the wire 64 is 5-20°.

[0038] Because there is an angle θ9 between the top surface 63 and the third part 23, when the first part 19 is pushed by the second type 32 (see Figure 3(a)) and a downward force is applied to the first part 19, the second part 21, and the third part 23, the third part 23 rotates in the direction of arrow D around the point of contact between the end 24 of the third part 23, which rests on the top surface 63, and the top surface 63. Since the base 62 allows displacement of the end 22 of the second part 21 (see Figure 2(b)), the deflection of the first part 19 can be further reduced.

[0039] Although the present invention has been described above based on embodiments, it can be easily inferred that the present invention is not limited in any way to the above embodiments, and that various improvements and modifications are possible without departing from the spirit of the present invention.

[0040] The shapes of the wires 12, 64 and the sheet pad 10 in the embodiment are examples only and are not limited thereto. For example, it is certainly possible to curve the wires 12, 64 from the first part 19 to the second part 21, or from the second part 21 to the third part 23. If the third part 23 is bent in the opposite direction to the bending of the second part 21, then when force is applied to the first part 19, the second part 21 and the third part 23 will bend, thereby reducing the bending of the first part 19.

[0041] In the embodiment, the fourth part 25 is directly attached to the third part 23 of the wires 12,64, and when the first part 19 of the wires 12,64, which are placed on the first mold 31, is pressed by the second mold 32, the third part 23 rotates around the point of contact between the wires 12,64 and the bases 35,52,62. However, the embodiment is not necessarily limited to this. It is certainly possible to create a wire shape in which a bent portion is provided between the third part 23 and the fourth part 25, and when the first part 19 is pressed by the second mold 32, the bent portion rotates around the point of contact between the wire and the bases 35,52,62.

[0042] In the embodiment, the case in which the first part 19 of the wires 12,64 is straight along its entire length has been described, but it is not necessarily limited to this. It is of course possible to bend the first part 19 at one or more points so that a part of the first part 19 approaches the straight line 27. This is because if the first part 19 includes a straight portion, the straight portion of the first part 19 located near the back surface 13 of the main body 11 can be used to fix the skin or frame.

[0043] Although not described in the third embodiment, it is naturally possible to provide a hook-shaped fastening portion connected to a projection 37 provided on the top surface 63 of the base 62, similar to the modification in the second embodiment. The end 24 of the third portion 23 of the hook-shaped fastening portion is positioned on the fourth portion 25 of the wire 64 which rests on the top surface 63. The fastening portion restricts the displacement of the fourth portion 25 in the direction of rotation around the straight line 27, preventing the fourth portion 25 from lifting off the base 62. If a fastening portion 55 is provided on the base 62, the fastening portion 38 can be omitted. [Explanation of Symbols]

[0044] 10 Seat Pads 12.64 wires 19 Part 1 20 The end of Part 1 21 Part 2 22 The end of Part 2 23 Part 3 24 The End of Part 3 25 Part 4 26 plane 27 straight line 30 mold 31,50,60 Type 1 32 Type 2 33 Space 34,51,54,61 Fixed part 36, 53, 63 Top surface (part of the first limiting section) 37. Protrusion (part of the first limiting portion) 38, 40, 55 Fixing part (part of the second limiting part)

Claims

1. A wire embedded in the seat pad, Part 1 includes a straight section, Two second parts adjacent to each of the two ends of the first part and bent in the same direction from one another, Two third parts adjacent to each end of the second part, which fold in the opposite direction to the direction in which the second part folds, It includes two fourth parts, each connected to the end of the third part and extending in a direction intersecting the plane containing the first and second parts, A wire in which the angle between the first part and the second part is obtuse, and the angle between the second part and the third part is obtuse.

2. The second part descends from the first part as it approaches the aforementioned end of the second part, The wire according to claim 1, wherein the third portion intersects with a straight line passing through the two ends of the second portion and descends from the second portion as it approaches the ends of the third portion.

3. A seat pad in which the wire described in claim 1 or 2 is embedded.

4. A molding die comprising a first type and a second type, wherein a sheet pad is formed in the space created by placing the second type over the first type, The first type includes a fixing part for arranging the wire described in claim 1 or 2 in the space, The fixing portion includes a first limiting portion that limits the displacement of the third portion in a direction along a straight line passing through the two ends of the second portion, A mold comprising: a second limiting portion that limits the displacement of the fourth portion in a direction of rotation around the aforementioned straight line.

5. The molding die according to claim 4, wherein the fixing portion allows displacement of the end of the second portion in a direction that brings the second portion closer to the first portion when creating the space, and in a direction that rotates around the first limiting portion.

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