Seat pad base

Abstract

Compared to conventional seat pads, there is a need to suppress defects caused by voids that can occur during the foam molding process of the pad portion. [Solution] The sheet pad of the present disclosure is a sheet pad in which a pad portion made of resin foam is formed on the upper surface and side surface of a base portion made of bead foam molded body, and the sheet pad comprises a recess formed on the side surface of the base portion and a porous body received in the recess.

Description

【Technical Field】 【0001】 The present disclosure relates to a seat pad. 【Background Art】 【0002】 There is known a seat pad in which a pad portion is integrally foam-molded on a base portion (see, for example, Patent Document 1). 【Prior Art Documents】 【Patent Documents】 【0003】 【Patent Document 1】 JP 2021-45261 (paragraphs 【0002】, 【0010】, 【0011】, FIGS. 1, 2, etc.) 【Summary of the Invention】 【Problems to be Solved by the Invention】 【0004】 There is a demand for suppressing defects caused by voids that may occur during the foam molding of the pad portion with respect to the above-described conventional seat pad. 【Means for Solving the Problems】 【0005】 A first aspect of the invention is a seat pad in which a pad portion including a resin foam is formed on an upper surface and a side surface of a base portion including a bead foam molding, the seat pad including a recess formed on the side surface of the base portion and a porous body received in the recess. 【Brief Description of the Drawings】 【0006】 [Figure 1] (A) Perspective view of the seat, (B) Side cross-sectional view of the seat pad [Figure 2] (A) Cross-sectional view taken along line A-A of the seat pad, (B) Perspective view of the periphery of the recess of the base portion [Figure 3] (A) Side cross-sectional view of the molding die in which the base portion is set in the upper die, (B) Side cross-sectional view of the pad portion foam-molded in the molding die [Figure 4] (A) Plan view of the recess, (B) Perspective view of the recess and the porous material to be received in the recess [Figure 5] Side cross-sectional view of the raw material for the resin foam being foamed in the molding die. [Figure 6] In the conventional manufacturing process of a seat pad, (A) a side cross-sectional view of the raw material for the pad portion being foamed in the molding die, and (B) a side cross-sectional view of the pad portion formed by the foaming and hardening of the raw material in the molding die. [Modes for carrying out the invention] 【0007】 As shown in Figures 1(A) and 1(B), the seat pad 10 according to one embodiment of the present disclosure is applied to a cushion pad used in the seating portion 91 of a seat in a vehicle or the like. The seating portion 91 is formed by covering the seat pad 10 with a cover 93. 【0008】 As shown in Figure 1(B), the seat pad 10 is formed by a pad portion 11 covering the base portion 20 from the seated side (from above). In this embodiment, the pad portion 11 is integrated with the upper surface 20J and the side surface 20S of the base portion 20. In this disclosure, the front, rear, left, and right surfaces of the base portion 20 are collectively referred to as the side surface 20S of the base portion 20. For example, in this embodiment, the pad portion 11 covers all of the side surface 20S of the base portion 20 (i.e., the front, rear, left, and right surfaces of the base portion 20), but it may cover at least some of the side surface 20S of the base portion 20. For example, the base portion 20 is in the shape of a block that is flattened in the vertical direction. 【0009】 In this embodiment, the pad portion 11 comprises a resin foam (for example, a thermosetting resin foam), and the base portion 20 comprises a bead foam molded body. 【0010】 If the pad portion 11 includes a thermosetting resin foam, the thermosetting resin foam may be, for example, a polyurethane-based resin foam, and may be a soft type. The pad portion 11 may be, for example, breathable or non-breathable. For example, a parting line L is formed at the boundary between the side and bottom surfaces of the pad portion 11 by the joint between the upper mold 71 and the lower mold 72 of the molding die 70, which will be described later. 【0011】 Examples of the bead foam molded body included in the base portion 20 include a bead foam molded body made of polystyrene resin or a bead foam molded body made of polyolefin resin (polyethylene resin, polypropylene resin, etc.). In this embodiment, the base portion 20 is non-permeable. 【0012】 A recess 21 is formed in the portion of the side surface 20S of the base portion 20 that is covered by the pad portion 11. The recess 21 is, for example, groove-shaped, and in this embodiment, it is a groove that extends vertically. Specifically, the recess 21 extends from the lower end of the base portion 20 to an intermediate position (for example, a position closer to the upper end of the base portion 20). The recess 21 may also be configured such that the opening 21K of the recess 21 is narrower than the interior of the recess 21. In this embodiment, the recess 21 is configured in this way, and protrusions 22 are formed on opposing surfaces (in this embodiment, the groove opening edges) that face each other in the groove width direction on the inner surface of the recess 21 (see Figures 2(A) and 2(B)). For example, the protrusions 22 extend over the entire vertical direction of the recess 21. In this embodiment, the outer surface of the protrusions 22 (the surface facing the pad portion 11) is substantially flush with the side surface 20S of the base portion 20. Furthermore, in this embodiment, the surface of one pair of protrusions 22 that faces the bottom surface 21M of the recess 21 is an inclined surface 23 that extends away from the bottom surface 21M as the pair of protrusions 22 approach each other in their opposing directions. 【0013】 A porous body 30 is received in the recess 21. In this embodiment, the width of the porous body 30 is wider than the distance between the pair of protrusions 22, and the porous body 30 is positioned on the inner side of the recess 21 relative to the pair of protrusions 22. Also, as shown in Figure 1(B), the upper end (end face 21T) of the inner surface of the recess 21 faces the porous body 30 from above (for example, it is in contact with it). In this embodiment, the porous body 30 is positioned so as to fit inside the recess 21 (for example, it is compressed). The porous body 30 may protrude from the recess 21. 【0014】 In this embodiment, the porous body 30 is a breathable foam (for example, a foam with an open-cell structure), and is made of, for example, slab urethane. 【0015】 In this embodiment, a portion of the resin foam (for example, thermosetting resin foam) constituting the pad portion 11 is embedded in the recess 21, and the raw material G (see Figure 3(A)) of this resin foam is impregnated into the porous body 30 and hardened. As a result, the porous body 30, which has been impregnated and hardened with the raw material G of the resin foam, has a higher hardness than the state in which the raw material G of the resin foam is not impregnated, and is also harder than the pad portion 11. In this way, the impregnation and hardening of the raw material G of the resin foam within the porous body 30 makes it possible to further stabilize the fixation of the pad portion 11 to the base portion 20. 【0016】 The recesses 21 and porous bodies 30 only need to be provided on at least a portion of the circumferential direction of the side surface 20S of the base portion 20, and may, for example, be provided around the entire circumference of the side surface 20S (for example, they may be annular). In addition, multiple sets of recesses 21 and porous bodies 30 may be provided, and may, for example, be arranged to surround the main body of the base portion 20 (for example, overall around the circumferential direction of the side surface 20S). 【0017】 The seat pad 10 of the present embodiment is manufactured as follows, for example. First, a base portion 20 (see FIG. 3(A)) having a recess 21 formed in its side surface 20S is prepared. The base portion 20 may be entirely formed of a bead foam, for example. The recess 21 (see FIG. 4(A)) of the base portion 20 may be formed simultaneously with the foam molding of the base portion 20, or may be formed after the foam molding thereof. 【0018】 A porous body 30 is received in the recess 21 of the base portion 20 (see FIG. 4(B)). For example, the porous body 30 is inserted into the recess 21 by being slid from one open end of the groove-shaped recess 21. In the example of the present embodiment, the porous body 30 has a plate shape, but it may have any size and shape suitable for being received in the recess 21, and is not limited thereto. For example, a porous body 30 having a volume larger than the volume of the recess 21 may be prepared and compressed to be packed in the recess 21. 【0019】 Then, as shown in FIG. 3(A), the base portion 20 is set on the upper mold 71 of the molding die 70. At this time, the base portion 20 is arranged upside down compared to when the seat pad 10 is used, and is set so that the lower surface 20K (the lower surface when the seat pad 10 is used) of the base portion 20 faces the upper mold 71 side. 【0020】 Then, a raw material G of a resin foam (specifically, a foam of a thermosetting resin such as a polyurethane-based resin, for example) is injected into the molding recess 72U of the lower mold 72 of the molding die 70, and the molding die 70 is closed. 【0021】 As shown in FIG. 5, when the raw material G of the resin foam foams and expands in the temperature-controlled and heated molding die 70, gases such as the foaming gas and the air in the molding die 70 can escape from the joint 70S between the upper mold 71 and the lower mold 72. For example, the joint 70S is provided with a vent (for example, a so-called ribbon vent or the like) formed in a groove shape in the upper mold 71 or the lower mold 72, and the vent makes it easier to escape the above-mentioned gas in the molding die 70 from the joint 70S. 【0022】 Here, as the raw material G of the resin foam in the pad portion 11 expands due to foaming, the gas inside the molding die 70 is pushed towards the base portion 20 and is likely to be trapped between the resin foam and the base portion 20. In particular, foaming of the raw material G occurs faster at higher temperatures, so if the temperature of the base portion 20 is lower than that of the molding die 70 due to the heat insulation properties of the base portion 20, the foamed raw material G is more likely to rise along the inner surface of the molding die 70 than along the surface of the base portion 20 (see Figure 5). 【0023】 Here, as shown in Figure 6(A), in a conventional seat pad having a base portion 20Z without a recess 21, when the pad portion 11 is foamed, if the joint 70S between the upper mold 71 and the lower mold 72 is blocked by the raw material G that rises along the inner surface of the lower mold 72 while foaming, the gas can become trapped between the resin foam and the base portion 20 (especially the side surface 20S), which can easily lead to the formation of voids 11S (see Figure 6(B)). When such voids 11S occur, the strength and cushioning properties of the pad portion 11 may be impaired, and discomfort when sitting may occur, potentially resulting in a defective product. Furthermore, when voids 11S occur, the strength of the seat pad 10 may decrease, making it difficult to wrap the cover 93 (see Figure 1(B)) around the lower surface of the seat pad 10. 【0024】 In contrast, in this embodiment, as described above, a recess 21 is formed on the side surface 20S of the base portion 20, and the porous body 30 is received in the recess 21. By providing the recess 21 in this way, the trapped gas can be released into the recess 21. Here, since the porous body 30 is placed in the recess 21, even if the gas remains in the recess 21, it is less likely that large voids 11S (see Figure 6(B)) will form as in the conventional method, thereby suppressing a decrease in strength and other problems caused by the formation of voids 11S. Furthermore, for example, the raw material G of the resin foam rises along the side surface 20S of the base portion 20 while foaming, impregnates the porous body 30, and then foams and hardens. In this way, by providing the porous body 30, it is possible to make it easier for the raw material G to rise along the side surface 20S of the base portion 20 while foaming compared to when the raw material G rises along the side surface 20S of the base portion 20 without the porous body 30. This is thought to make it possible to further suppress the formation of voids 11S between the side surface 20S of the base portion 20 and the pad portion 11. 【0025】 When the raw material G of the resin foam further foams and expands, covering the side surface 20S of the base portion 20 and hardening, a pad portion 11 is formed that is integrated with the upper surface 20J and side surface 20S of the base portion 20 (see Figure 3(B)). 【0026】 For example, multiple vents may be arranged in a row along the opening edge of the molding recess 72U of the lower mold 72. When multiple recesses 21 of the base portion 20 are arranged in a row in the circumferential direction of the side surface 20S of the base portion 20, the vents and recesses 21 may be placed in the same position or in offset positions in the circumferential direction of the side surface 20S of the base portion 20. 【0027】 In the seat pad 10 of this embodiment, impregnation and curing of the resin foam raw material G into the porous body 30 makes it possible to suppress the decrease in strength of the portion within the recess 21. Furthermore, since the porous body 30 is received in the recess 21 of the base portion 20, it is possible to suppress discomfort when a person sits on the pad portion 11 compared to when the entire porous body 30 protrudes from the side surface 20S of the base portion 20. 【0028】 Furthermore, in this embodiment, since the opening of the recess 21 is narrower than the interior of the recess 21 in the base portion 20, it is possible to prevent the porous body 30 from falling out of the recess 21 when setting the base portion 20 in the molding die 70. 【0029】 Furthermore, since the recess 21 is groove-shaped and extends vertically, it is possible to easily guide the gas inside the molding die 70 in the vertical direction by the recess 21 during foam molding of the pad portion 11. In addition, the inner surface of the recess 21 of the base portion 20 is provided with an opposing portion (end face 21T) that faces the porous body 30 from above. Therefore, when setting the base portion 20 upside down in the molding die 70, the porous body 30 can be supported by the end face 21T, preventing the porous body 30 from falling out of the recess 21 of the base portion 20. 【0030】 [Other embodiments] (1) In the above embodiment, the seat pad 10 can also be applied to the back pad used in the backrest portion 92 of the seat (see Figure 1(A)). In this case, the seat pad 10 can be configured such that the pad portion 11 is integrated with the base portion 20 from the seated side (front side). 【0031】 (2) The seat pad 10 may be used in seats inside vehicles or in seats inside buildings. 【0032】 (3) The base portion 20 may be entirely made of a bead foam molded body or only partially made of a bead foam. The pad portion 11 may be entirely made of a resin foam or only partially made of a resin foam. 【0033】 (4) The porous body 30 may be made of a breathable foam (for example, a foam with an open-cell structure), or it may be made of a fibrous material such as a nonwoven fabric or felt. 【0034】 (5) The protrusion 22 may be divided into multiple parts in the direction in which the groove-shaped recess 21 extends (up and down in the above embodiment), or it may be provided in one place in the direction in which the recess 21 extends. Alternatively, the protrusion 22 may not be provided at all. 【0035】 (6) The recess 21 may be a dovetail groove in which the groove width gradually narrows from its bottom surface 21M toward the opening 21K. Alternatively, the recess 21 may be configured in which the groove width widens from its bottom surface 21M toward the opening 21K, or the groove width may be constant. 【0036】 (7) The recess 21 may be a through groove that crosses the base portion 20 in the vertical direction. The recess 21 does not have to extend to the upper or lower end of the base portion 20. The recess 21 does not have to be groove-shaped. 【0037】 (8) The raw material G of the resin foam of the pad portion 11 does not need to be impregnated into the porous body 30. 【0038】 <Note> The following describes the features extracted from the above embodiment, explaining their effects and other aspects as needed. 【0039】 For example, the following set of features can be considered to have been conceived with the background technology that "a sheet pad is known in which the pad portion is integrally foam-molded with the base portion (see, for example, Japanese Patent Application Publication No. 2021-45261 (paragraphs

[0002] ,

[0010] ,

[0011] , Figures 1 and 2, etc.))" and the problem that "there is a need to suppress defects caused by voids that may occur during the foam molding of the pad portion compared to the conventional sheet pad described above." Furthermore, there has been a long-standing demand for novel sheet pads and novel methods for manufacturing sheet pads. 【0040】 [Feature 1] A sheet pad having a base portion comprising a bead foam molded body, with a pad portion comprising a resin foam formed on the upper surface and side surface of the base portion comprising a bead foam molded body, The recess formed on the side surface of the base portion, A sheet pad comprising a porous body received in the aforementioned recess. 【0041】 In this feature, recesses are formed on the sides of the base. This allows gas to escape into the recesses during foam molding of the pad. Furthermore, since a porous material is provided within the recesses, the generation of large voids can be suppressed compared to cases without a porous material, thereby reducing defects caused by voids. 【0042】 [Feature 2] The seat pad according to feature 1, wherein the opening of the recess is narrower than the interior of the recess. 【0043】 This feature makes it possible to prevent the porous material from falling out of the recessed areas. 【0044】 [Feature 3] The aforementioned recess is groove-shaped and extends vertically. The sheet pad according to feature 1 or 2, wherein the inner surface of the recess is provided with an opposing portion that faces the porous body from above. 【0045】 This feature makes it easier to guide the gas inside the mold vertically through the recesses during foam molding of the pad portion. Furthermore, this feature prevents the porous material from falling out of the recesses when the base portion 20 is set upside down in the mold. 【0046】 [Feature 4] The sheet pad according to any one of the features 1 to 3, wherein the porous material is a foam with an open-cell structure. 【0047】 [Feature 5] The sheet pad according to any one of the features 1 to 4, wherein the porous body is impregnated and hardened with the raw material of the resin foam. 【0048】 This feature makes it possible to suppress the decrease in strength of the recessed portion of the seat pad. 【0049】 [Feature 6] The sheet pad according to feature 5, wherein the porous body impregnated and hardened with the aforementioned raw material has a harder hardness than the pad portion. 【0050】 This feature makes it possible to suppress the decrease in strength of the recessed portion of the seat pad. 【0051】 [Feature 7] A method for manufacturing a sheet pad, comprising setting a base portion having a bead foam molded body into the upper mold of a mold, foaming the raw material for a resin foam within the mold, and forming a pad portion on the upper surface and side surface of the base portion, A method for manufacturing a sheet pad, comprising forming a recess on the side of the base portion that is covered by the pad portion, and receiving a porous body in the recess to form the resin foam. 【0052】 In this feature, a recess is provided on the side of the base, allowing gas to escape into the recess during foam molding of the pad. Furthermore, since a porous material is provided within the recess, the generation of large voids can be suppressed compared to when there is no porous material, thereby suppressing defects caused by voids. 【0053】 [Feature 8] A bead foam molded body in which the top and sides of a pad portion comprising a resin foam are covered, and together with the pad portion, constitutes a sheet pad, The recess formed on the aforementioned side surface, A bead foam molded body comprising a porous body received in the recess. 【0054】 While this specification and drawings disclose specific examples of the technology included in the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and changes to these examples, as well as parts of the examples taken individually. [Explanation of Symbols] 【0055】 10 Seat Pads 11 Pad section 20 Base section 21 Recess 30 Porous material

Claims

[Claim 1] A sheet pad having a base portion comprising a bead foam molded body, with a pad portion comprising a resin foam formed on the upper surface and side surface of the base portion comprising a bead foam molded body, The recess formed on the side surface of the base portion, A sheet pad comprising a porous body received in the aforementioned recess. [Claim 2] The seat pad according to claim 1, wherein the opening of the recess is narrower than the interior of the recess. [Claim 3] The aforementioned recess is groove-shaped and extends vertically. The sheet pad according to claim 1 or 2, wherein the inner surface of the recess is provided with an opposing portion that faces the porous body from above. [Claim 4] The sheet pad according to claim 1 or 2, wherein the porous body is a foam with an open-cell structure. [Claim 5] The sheet pad according to claim 1 or 2, wherein the porous body is impregnated and cured with the raw material of the resin foam. [Claim 6] The sheet pad according to claim 5, wherein the porous body impregnated and hardened with the aforementioned raw material has a harder hardness than the pad portion. [Claim 7] A method for manufacturing a sheet pad, comprising setting a base portion having a bead foam molded body into the upper mold of a mold, foaming the raw material for a resin foam within the mold, and forming a pad portion on the upper surface and side surface of the base portion, A method for manufacturing a sheet pad, comprising forming a recess on the side of the base portion that is covered by the pad portion, and receiving a porous body in the recess to form the resin foam.

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