Sheet pad

Abstract

To provide a seat pad capable of reducing generation of abnormal sound due to a part formed of foaming foam which is wrapped around the part and solidified there, a small pad and a manufacturing method of the seat pad.SOLUTION: A seat pad comprises a pad body made of a soft foam and a small pad made of an elastic body. The small pad includes a body part having a first face exposed from the pad body and a second face coming into contact with the pad body, and a flange projecting from the body part. The flange includes a first flange face being adjacent to the first face, a tip face being adjacent to the first flange face and coming into contact with the pad body, and a second flange face being adjacent to the tip face and the second face and coming into contact with the pad body. The small pad is so configured that an area of the flange projected on a plane parallel to the first flange face is smaller than an area of the body part projected to the plane.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a seat pad in which a small pad made of an elastic body and a pad body made of a soft foam are integrated. Doh It relates to.

Background Art

[0002] A seat pad in which a small pad made of an elastic body and a pad body made of a soft urethane foam are integrated is known (Patent Document 1). This type of seat pad is manufactured by fixing a small pad to the surface of the first mold cavity and then foaming the raw material liquid of the pad body between the first mold and the second mold to integrate the pad body and the small pad. If the foam during foaming encroaches into the gap formed between the surface of the first mold cavity and the small pad, the surplus portion where the foam has encroached and solidified may rub against the vehicle body and cause abnormal noise. In the technique disclosed in Patent Document 1, a small pad provided with a recess is prepared, and a wall provided on the surface of the first mold cavity is fitted into the recess of the small pad to reduce the gap between the cavity surface and the small pad and reduce the encroachment of the foam during foaming.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, there is room for improvement in this technique.

[0005] The present invention has been made to meet this requirement, and provides a seat pad capable of reducing the generation of abnormal noise caused by the portion where the foam has encroached and solidified. Doh The purpose is to provide.

Means for Solving the Problems

[0006] To achieve this object, the seat pad of the present invention includes a pad body made of a soft foam and a small pad made of an elastic body. The small pad includes a main body portion having a first surface exposed from the pad body and a second surface in contact with the pad body, and a flange projecting from the main body portion. The flange includes a first flange surface adjacent to the first surface, a tip surface adjacent to the first flange surface and in contact with the pad body, and a second flange surface adjacent to the tip surface and the second surface and in contact with the pad body. The small pad has an area of the flange projected on a plane parallel to the first flange surface smaller than an area of the main body portion projected on the same plane. Ku, there is no recess that penetrates the flange in the thickness direction and no recess that extends along the entire edge of the first flange surface .

[0007]

[0008]

Advantages of the Invention

[0009] According to the seat pad of the present invention, since the small pad has a flange projecting from the main body portion, it becomes difficult for the foam in the process of foaming to overflow onto the first surface of the main body portion during the manufacture of the seat pad by the amount of the projection of the flange. Since the small pad has an area of the flange projected on a plane parallel to the first flange surface smaller than an area of the main body portion projected on the same plane, when a force is applied to the pad body substantially perpendicular to the plane, the force applied to the flange is smaller than the force applied to the main body portion. Since the applied force is small, it is possible to reduce abnormal noise caused by contact between the portion where the foam in the process of foaming has overflowed and solidified on the first flange surface and the body.

[0010]

[0011]

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0013] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Fig. 1 is a cross-sectional view of the sheet pad 10 in the first embodiment. The arrows X, Y, Z in Fig. 1 respectively indicate the first direction, the second direction, and the third direction that are orthogonal to each other of the sheet pad 10 and the small pad 30 (the same also applies in Figs. 2 to 7). In Fig. 1, the illustration of the back material and the like arranged on the sheet pad 10 is omitted. The sheet pad 10 is integrated with a pad body 20 made of a soft foam such as soft polyurethane foam and a small pad 30 made of an elastic body.

[0014] The seat pad 10 is used as a cushioning material for the seats of vehicles such as automobiles and ships. The surface 11 of the seat pad 10 is the surface that comes into contact with the buttocks and thighs of the seated person and is formed by the pad body 20. A small pad 30 is disposed on the back surface 12 of the seat pad 10 on the opposite side of the surface 11 so as to be embedded in the pad body 20. The back surface 12 of the seat pad 10 is the surface that comes into contact with the vehicle body (not shown). The pad body 20 is provided with a hole 13 that connects the surface 11 of the seat pad 10 and the small pad 30. The hardness of the pad body 20 can be reduced by the amount of the hole 13.

[0015] The elastic body constituting the small pad 30 is, for example, a foam or a porous body in which continuous bubbles or independent bubbles are dispersed in a synthetic resin. The elastic body has heat resistance and mechanical strength that can withstand the heat during the molding of the pad body 20, and can be used without particular limitation as long as the material type is different from that of the soft foam which is the material of the pad body 20. Examples of the synthetic resin constituting the elastic body include polyolefins such as polyethylene and polypropylene, polystyrene, polyurethane, phenol resin, and polyvinyl chloride. The material of the elastic body may also be rubber or elastomer.

[0016] The elastic body constituting the small pad 30 can be appropriately selected and used from those having different densities and hardnesses from the soft foam. By using an elastic body having a lower density than the soft foam, the seat pad 10 can be lightened accordingly. By using an elastic body having a greater hardness than the soft foam, the hardness of the seat pad 10 can be increased accordingly. When the small pad 30 made of an elastic body having a lower density and a greater hardness than the soft foam (for example, foamed polypropylene or foamed polystyrene) is embedded in the pad body 20, it is possible to reduce the weight of the seat pad 10 and increase its hardness.

[0017] The small pad 30 includes a main body portion 31 and a flange 32 protruding from the main body portion 31. The main body portion 31 has a first surface 33 exposed from the pad main body 20 and a second surface 34 in contact with the pad main body 20. The hole 13 of the pad main body 20 is connected to the second surface 34. The entire first surface 33 of the main body portion 31 forms a part of the back surface 12 of the sheet pad 10.

[0018] The flange 32 includes a first flange surface 35 adjacent to the first surface 33, a tip surface 37 adjacent to the first flange surface 35, and a second flange surface 36 adjacent to the tip surface 37 and the second surface 34 of the main body portion 31. The tip surface 37 and the second flange surface 36 are in contact with the pad main body 20. The tip surface 37 is the farthest from the main body portion 31 in the first direction (X direction). The edge 35a of the first flange surface 35 is located on the back surface 12 of the sheet pad 10 and is in contact with the pad main body 20.

[0019] The length of the flange 32 in the first direction (X direction) between the base of the flange 32 of the main body portion 31 and the tip surface 37 is greater than the thickness of the flange 32 in the second direction (Y direction) perpendicular to the first direction. This makes the flange 32 more likely to bend compared to the case where the thickness of the flange 32 is greater than the length of the flange 32. For example, the length of the flange 32 is 30 - 100 mm, and the thickness of the flange 32 is 10 - 30 mm. The thickness of the main body portion 31 in the second direction is greater than the thickness of the flange 32.

[0020] The small pad 30 is provided with a first recess 38 recessed toward the second flange surface 36 at the boundary between the first surface 33 of the main body portion 31 and the first flange surface 35 of the flange 32. The small pad 30 is provided with a first recess 39 recessed toward the first flange surface 35 at the boundary between the second surface 34 of the main body portion 31 and the second flange surface 36 of the flange 32. The first recesses 38, 39 extend in the width direction of the flange 32, and both ends of the first recess 38 are connected to the edge 35a of the first flange surface 35. Both ends of the first recess 39 are also connected to the edge of the second flange surface 36.

[0021] Since the distance between the first flange surface 35 and the second flange surface 36 is shortened by the first recesses 38 and 39, the flange 32 is more likely to bend. This is particularly effective when the hardness of the small pad 30 is greater than the hardness of the pad body 20. Since the first recess 39 is provided between the second flange surface 36 and the second surface 34, the contact area between the flange 32 and the pad body 20 increases by the amount of the first recess 39. Therefore, the bonding strength between the flange 32 and the pad body 20 can be improved.

[0022] A second recess 40 that penetrates from the first flange surface 35 to the second flange surface 36 is formed in the flange 32. The pad body 20 is in contact with the second recess 40. Since the contact area between the flange 32 and the pad body 20 increases by the amount of the second recess 40, the bonding strength between the flange 32 and the pad body 20 can be improved. When the hardness of the small pad 30 is greater than the hardness of the pad body 20, the cross-sectional area of the flange 32 is reduced by the amount of the second recess 40, so the hardness of the flange 32 can be reduced.

[0023] With reference to FIGS. 2(a) and 2(b), a method for manufacturing the sheet pad 10 will be described. FIG. 2(a) is a cross-sectional view of the mold 50 with the small pad 30 attached. FIG. 2(b) is a cross-sectional view of the closed mold 50. In FIGS. 2(a) and 2(b), the illustration of the backing material disposed in the mold 50 is omitted. The backing material is a non-woven fabric or the like disposed on the back surface 12 of the sheet pad 10, and the reinforcing material is a suspension wire, a resin clip, a frame, or the like embedded in the pad body 20.

[0024] The sheet pad 10 is manufactured by a mold 50. The mold 50 includes a first mold 51 and a second mold 52, and a hinge 53 that connectably opens and closes the first mold 51 and the second mold 52. When the mold 50 is closed, a cavity 54 is formed between the first mold 51 and the second mold 52. The portion including the back surface 12 of the sheet pad 10 is formed by the cavity surface 55 of the first mold 51, and the portion including the front surface 11 of the sheet pad 10 is formed by the cavity surface 56 of the second mold 52.

[0025] On the cavity surface 55 of the first mold 51, pins 57 for attaching the small pad 30 are provided. On the cavity surface 56 of the second mold 52, protrusions 58 are provided that protrude toward the cavity surface 55 of the first mold 51 when the mold 50 is closed. The protrusions 58 may be provided at multiple locations on the second mold 52 depending on the size and shape of the small pad 30.

[0026] Referring to FIGS. 3(a) and 3(b), the small pad 30 attached to the first mold 51 will be described. FIG. 3(a) is a rear view of the small pad 30 as viewed from the direction of arrow IIIa in FIG. 2. FIG. 3(b) is a cross-sectional view of the small pad 30 taken along line IIIb-IIIb in FIG. 3(a). In FIGS. 3(a) and 3(b), a part of the main body 31 is not shown (the same applies to FIGS. 4(a) to 7(c)).

[0027] As shown in FIG. 3(a), the first recess 38 adjacent to the first surface 33 of the main body 31 and the first flange surface 35 of the flange 32 has a groove with a semi-circular cross-sectional shape and is connected to the edge 35a of the first flange surface 35. The cross-sectional shape of the first recess 38 is not limited to a semi-circle and may be a polygon such as a triangle or a quadrilateral. The first recess 39 adjacent to the second surface 34 of the main body 31 and the second flange surface 36 of the flange 32 is also provided over the entire length in the width direction (Z direction) of the flange 32, similar to the first recess 38.

[0028] The second recesses 40 that penetrate the flange 32 in the thickness direction are provided at multiple locations (three locations in this embodiment) on the flange 32, spaced apart from each other in the width direction of the flange 32. In this embodiment, the cross-sectional shape of the second recess 40 is circular, but it is not limited to this and may be an ellipse, a polygon such as a triangle or a quadrilateral.

[0029] As shown in Fig. 3(b), in the state before the small pad 30 is attached to the first mold 51, the flange 32 is inclined so that the angle θ formed between the first surface 33 of the main body 31 and the first flange surface 35 of the flange 32 is 135° or more and less than 180°. The angle θ refers to the angle formed by a line segment connecting the boundary between the first surface 33 of the main body 31 and the first flange surface 35 of the flange 32 and the edge 35a of the first flange surface 35, and the portion of the first surface 33 closest to the first flange surface 35. The sheet pad 10 in which the small pad 30 is integrated with the pad main body 20 is equal to a plane in which the plane projecting the flange 32 and the main body 31 is parallel to this line segment (see Fig. 1).

[0030] Returning to Fig. 2(a) for explanation. In the attachment process of attaching the small pad 30 to the first mold 51, the pin 57 is fitted into the hole 31a provided in the main body 31 so that the cavity surface 55 of the first mold 51, the first surface 33 of the main body 31 of the small pad 30, and the first flange surface 35 of the flange 32 face each other, and the small pad 30 is fixed to the first mold 51. When fixing the small pad 30 to the first mold 51, there may be a gap 59 between the base of the flange 32 and the cavity surface 55.

[0031] After mixing the raw material liquid of the soft urethane foam and supplying it from an injection device (not shown) to the second mold 52, in the mold closing process, the molding die 50 is closed as shown in Fig. 2(b). The position and length of the protrusion 58 are set so as to press the main body 31 of the small pad 30 against the first mold 51 when the molding die 50 is closed. Along with the mold closing, the small pad 30 is pressed toward the first mold 51 by the protrusion 58. When there is a gap 59 in the attachment process, the gap 59 disappears or becomes smaller in the mold closing process.

[0032] The first surface 33 of the main body 31 of the small pad 30 is pressed against the cavity surface 55 by the force with which the protrusion 58 presses the main body 31. The small pad 30 is made of an elastic body, and since the first flange surface 35 of the flange 32 is inclined with respect to the first surface 33 of the main body 31, when the first surface 33 of the main body 31 and the first flange surface 35 of the flange 32 are pressed against the cavity surface 55, the flange 32 elastically deforms (bends). In addition to the force with which the protrusion 58 presses the main body 31, the first flange surface 35 of the flange 32 strongly presses the cavity surface 55 by the restoring force of the elastic deformation of the flange 32.

[0033] Since the angle θ formed by the first surface 33 of the main body 31 of the small pad 30 and the first flange surface 35 of the flange 32 is 135° or more and less than 180°, depending on the shape of the cavity surface 55, when the small pad 30 is pressed against the cavity surface 55, it is possible to generate a desired restoring force in the flange 32 while preventing damage to the flange 32. To prevent damage to the flange 32, the angle θ is more preferably 165° or more and 178° or less.

[0034] The raw material liquid supplied to the second mold 52 foams and fills the cavity 54 while contacting the second surface 34, the second flange surface 36, and the tip surface 37 of the small pad 30 in the molding process, and becomes the pad body 20 having a hole 13 in the portion of the protrusion 58. The first flange surface 35 of the flange 32 is pressed against the cavity surface 55 by the force obtained by adding the restoring force of the flange 32 to the force with which the protrusion 58 presses the main body 31. Therefore, it is difficult for a gap to be generated between the first flange surface 35 and the cavity surface 55 through which the foam during foaming can penetrate. Therefore, it is difficult for a portion where the foam that has penetrated into the gap solidifies to occur on the first flange surface 35.

[0035] Depending on the material and shape of the small pad 30, the vicinity of the edge 33a of the first surface 33 of the small pad 30 may be deformed by the temperature of the mold 50 in the molding process and the heat generated by the reaction of the raw material liquid, and the vicinity of the edge 33a may warp to form a gap between the edge 33a and the cavity surface 55. If the foam during foaming wraps around and solidifies in this gap, the solidified portion may rub against the vehicle body and cause abnormal noise.

[0036] In order to reduce the occurrence of the form wrapping around this form, it is preferable to provide a flange 32 that protrudes from the main body 31 at a location near the edge 33a of the first surface 33 where warping is likely to occur. This is because even if the flange 32 is deformed during the molding process, it is difficult for a gap to occur between the edge 35a of the first flange surface 35 and the cavity surface 55 due to the restoring force of the flange 32. Therefore, the flange 32 may be selectively provided at the portion of the first surface 33 of the main body 31 where warping is likely to occur. The flange 32 may be provided around the entire circumference of the edge 33a of the first surface 33 of the main body 31.

[0037] Since the length (dimension in the X direction) of the flange 32 is larger than the thickness (dimension in the Y direction) of the flange 32, the flange 32 can be easily deformed according to the shape of the cavity surface 55 during the mold closing process. Furthermore, since the first recesses 38 and 39 and the second recess 40 are provided in the small pad 30, the flange 32 can be easily deformed according to the shape of the cavity surface 55. Since a plurality of second recesses 40 are provided at intervals in the width direction of the flange 32, deformation due to bending and torsion in the width direction (Z direction) of the flange 32 is likely to occur, and the flange 32 can be further easily deformed according to the shape of the cavity surface 55.

[0038] The seat pad 10 has a small pad 30 embedded in a pad body 20 made of a soft foam. Since the small pad 30 has a flange 32 that protrudes from the main body 31, it becomes difficult for the foam to reach the first surface 33 of the main body 31 by the amount that the flange 32 protrudes. Since the area of the flange 32 projected onto a plane parallel to the first flange surface 35 of the small pad 30 is smaller than the area of the main body 31 projected onto that plane, when the seat pad 10 is used by a seated person and a force is applied to the pad body 20 substantially perpendicular to that plane, the force applied to the flange 32 is smaller than the force applied to the main body 31. The smaller the force applied to the flange 32 and the main body 31, the less likely it is for abnormal noise caused by the portion where the foam has wrapped around and solidified to occur. Therefore, even if there is form wrapping around the first flange surface 35, it is possible to reduce the abnormal noise generated by the rubbing between the portion where the foam has wrapped around and solidified on the first flange surface 35 and the vehicle body.

[0039] The second embodiment will be described with reference to FIGS. 4(a) and 4(b). In the first embodiment, the case where the second recess 40 penetrating the flange 32 in the thickness direction is provided in the flange 32 was described. In the second embodiment, the case where the second recesses 61 and 62, which are recesses not penetrating the flange 32, are provided in the flange 32 will be described. For the parts identical to those described in the first embodiment, the same reference numerals will be given and the following description will be omitted.

[0040] FIG. 4(a) is a rear view of the small pad 60 in the second embodiment. FIG. 4(b) is a cross-sectional view of the small pad 60 taken along line IVb-IVb of FIG. 4(a). The small pad 60, similarly to the small pad 30, is integrated with the pad body 20 to form the sheet pad 10.

[0041] The small pad 60 has spherical crown-shaped second recesses 61 that are recessed toward the second flange surface 36 at a plurality of locations (three locations in this embodiment) on the first flange surface 35 of the flange 32, and are provided at intervals from each other in the width direction (Z direction) of the flange 32. The small pad 60 has spherical crown-shaped second recesses 62 that are recessed toward the first flange surface 35 at a plurality of locations (three locations in this embodiment) on the second flange surface 36 of the flange 32, and are provided at intervals from each other in the width direction of the flange 32. The positions, shapes, and numbers of the second recesses 61 and 62 are set as appropriate.

[0042] Since the second recesses 61 and 62 are provided on the first flange surface 35 and the second flange surface 36 of the small pad 60, the flange 32 is more likely to bend. Therefore, when the small pad 60 is attached to the first mold 51, the flange 32 can be easily deformed according to the shape of the cavity surface 55. Since the contact area between the pad body 20 and the second flange surface 36 increases by the amount of the second recess 62, the joining strength between the flange 32 and the pad body 20 can be improved. Further, since the second recesses 61 and 62 do not penetrate the flange 32 and the second recess 61 does not connect to the edge 35a of the first flange surface 35, it is possible to prevent the soft foam from entering the first flange surface 35 from the second recesses 61 and 62.

[0043] Referring to FIGS. 5(a) and 5(b), the third embodiment will be described. In the second embodiment, the case where the second recesses 61 and 62 are provided at intervals in the width direction (Z direction) of the flange 32 was described. In the third embodiment, the case where the second recesses 71 and 72 extending in the width direction of the flange 32 are provided in the flange 32 will be described. For the parts identical to those described in the first embodiment, the same reference numerals will be given and the following description will be omitted.

[0044] FIG. 5(a) is a rear view of the small pad 70 in the third embodiment. FIG. 5(b) is a cross-sectional view of the small pad 70 taken along line Vb-Vb of FIG. 5(a). Similar to the small pad 30, the small pad 70 is integrated with the pad body 20 to form the sheet pad 10.

[0045] The small pad 70 is provided with a second recess 71 recessed toward the second flange surface 36 on the first flange surface 35 (one place in this embodiment) of the flange 32. The second recess 71 extends in the width direction of the flange 32, and both ends of the second recess 71 are connected to the edge 35a of the first flange surface 35. The small pad 70 is provided with a second recess 72 recessed toward the first flange surface 35 on the second flange surface 36 (one place in this embodiment) of the flange 32. The second recess 72 extends in the width direction of the flange 32, and both ends of the second recess 72 are connected to the edge of the second flange surface 36.

[0046] Since the second recesses 71 and 72 are provided on the first flange surface 35 and the second flange surface 36 of the small pad 70, the flange 32 is more likely to bend. Therefore, when the small pad 70 is attached to the first mold 51, the flange 32 can be easily deformed according to the shape of the cavity surface 55. Since the contact area between the pad body 20 and the second flange surface 36 increases by the amount of the second recess 72, the bonding strength between the flange 32 and the pad body 20 can be improved.

[0047] Referring to FIGS. 6(a) and 6(b), the fourth embodiment will be described. In the third embodiment, the case where the second recesses 71 and 72 extending in the width direction (Z direction) of the flange 32 are provided in the flange 32 was described. In the fourth embodiment, the case where the second recesses 81 and 82 extending in the length direction (X direction) of the flange 32 are provided in the flange 32 will be described. For the parts identical to those described in the first embodiment, the same reference numerals will be given and the following description will be omitted.

[0048] FIG. 6(a) is a rear view of the small pad 80 in the fourth embodiment. FIG. 6(b) is a cross-sectional view of the small pad 80 taken along line VIb-VIb of FIG. 6(a). Similar to the small pad 30, the small pad 80 is integrated with the pad body 20 to form the sheet pad 10.

[0049] The small pad 80 is provided with second recesses 81 recessed toward the second flange surface 36 at a plurality of locations (three locations in this embodiment) on the first flange surface 35 of the flange 32. The second recess 81 extends in the length direction of the flange 32 from the edge where the tip surface 37 of the flange 32 and the first flange surface 35 intersect among the edges 35a of the first flange surface 35 toward the main body portion 31. The second recess 81 is separated from the first recess 38.

[0050] The small pad 80 is provided with second recesses 82 recessed toward the first flange surface 35 at a plurality of locations (three locations in this embodiment) on the second flange surface 36 of the flange 32. The second recess 82 extends in the length direction of the flange 32 from the edge where the tip surface 37 of the flange 32 and the second flange surface 36 intersect among the edges of the second flange surface 36 toward the main body portion 31. The second recess 82 is separated from the first recess 39.

[0051] Since the second recesses 81 and 82 are provided on the first flange surface 35 and the second flange surface 36 of the small pad 80, the flange 32 is more likely to bend. Therefore, when the small pad 80 is attached to the first mold 51, the flange 32 can be easily deformed according to the shape of the cavity surface 55. Since the contact area between the pad body 20 and the second flange surface 36 increases by the amount of the second recess 82, the bonding strength between the flange 32 and the pad body 20 can be improved.

[0052] If the foam penetrates into the second recess 81, the contact area between the pad body 20 and the first flange surface 35 increases by the amount of the second recess 81, so that the bonding strength between the flange 32 and the pad body 20 can be improved. If the amount of the foam penetrating into the second recess 81 is small, the gas generated when the raw material liquid foams and reacts and the air remaining in the mold 50 can be stored in the second recess 81. Due to the residual gas, the lack of the soft foam that easily occurs between the tip surface 37 of the small pad 80 and the pad body 20 can be reduced.

[0053] The fifth embodiment will be described with reference to FIGS. 7(a), 7(b) and 7(c). In the third embodiment, the case where the second recesses 71 and 72 extending in the width direction (Z direction) of the flange 32 are provided in the flange 32 was described. In the fourth embodiment, the case where the second recesses 81 and 82 extending in the length direction (X direction) of the flange 32 are provided in the flange 32 was described. In the fifth embodiment, the case where the second recesses 71, 72, 81, and 82 are provided in the flange 32 will be described. The same parts as those described in the first embodiment will be denoted by the same reference numerals, and the following description will be omitted.

[0054] FIG. 7(a) is a rear view of the small pad 90 in the fifth embodiment. FIG. 7(b) is a cross-sectional view of the small pad 90 taken along line VIIb-VIIb of FIG. 7(a). The small pad 90 is integrated with the pad body 20 to form the sheet pad 10, similar to the small pad 30.

[0055] The second recesses 71 and 81 are provided in the first flange surface 35 of the small pad 90, and the second recesses 72 and 82 are provided in the second flange surface 36. The second recesses 71 and 81 intersect with each other, and the second recesses 72 and 82 intersect with each other. This makes the flange 32 more likely to bend. Therefore, when the small pad 90 is attached to the first mold 51, the flange 32 can be more easily deformed according to the shape of the cavity surface 55.

[0056] Since the contact area between the pad body 20 and the second flange surface 36 increases by the amount of the second recesses 72 and 82, the bonding strength between the flange 32 and the pad body 20 can be improved. Also, since the contact area between the pad body 20 and the first flange surface 35 increases by the amount of the second recesses 71 and 81, the bonding strength between the flange 32 and the pad body 20 can be improved. Further, similar to the fourth embodiment, the cutout of the soft foam can be reduced by the second recess 81.

[0057] As described above, the present invention has been described based on the embodiments. However, it can be easily inferred that the present invention is not limited to the above embodiments at all, and various improvements and modifications are possible without departing from the spirit of the present invention.

[0058] In the embodiment, the seat pad 10 has been described by exemplifying the cushion pad, but the present invention is not limited thereto. It is of course possible to apply the seat pad 10 to a back pad.

[0059] In the embodiment, the case where the seat pad 10 is manufactured using the molding die 50 in which the first mold 51 and the second mold 52 form the cavity 54 has been described, but the present invention is not necessarily limited thereto. It is of course possible to manufacture the seat pad 10 using a molding die in which a core is provided between the first mold 51 and the second mold 52.

[0060] In the embodiment, the case where the cavity surface 55 of the first mold 51 is substantially flat has been described, but the present invention is not limited thereto. It is of course possible to set a curved surface, a step, or the like on the cavity surface 55. The shapes of the first surface 33 and the first flange surface 35 of the small pad are set according to the shape of the cavity surface 55.

[0061] In the embodiment, a back material (not shown) disposed on the seat pad 10 and the molding die 50 has been provided, but the present invention is not limited thereto. The back material may not be provided.

[0062] In the embodiment, the small pad in which the flange 32 projects a part of the periphery of the main body 31 has been described, but it is not limited to this. The flange 32 may be provided at a plurality of locations on the periphery of the main body 31, or may be provided on the entire periphery of the main body 31.

[0063] In the embodiment, the case where the first concave portion 38 and the second concave portion 71 of the flange 32 are continuously provided over the entire width direction of the first flange surface 35 has been described, but it is not necessarily limited to this. It is of course possible to intermittently provide the first concave portion 38 or the second concave portion 71 over the entire width direction of the first flange surface 35, or to provide the first concave portion 38 or the second concave portion 71 in a part of the width direction of the first flange surface 35.

[0064] In the embodiment, the case where the first concave portion 39 and the second concave portion 72 of the flange 32 are continuously provided over the entire width direction of the second flange surface 36 has been described, but it is not necessarily limited to this. It is of course possible to intermittently provide the first concave portion 39 or the second concave portion 72 over the entire width direction of the second flange surface 36, or to provide the first concave portion 39 or the second concave portion 72 in a part of the width direction of the second flange surface 36. Depending on the shape of the main body 31 and the flange 32, it is of course possible to bend the first concave portions 38, 39 and the second concave portions 71, 72 or change their widths and depths.

[0065] In the embodiment, the case where the first concave portion 38 is provided on the first flange surface 35 and the first concave portion 39 is provided on the second flange surface 36, and the second concave portions 61, 71, 81 are provided on the first flange surface 35 and the second concave portions 62, 72, 82 are provided on the second flange surface 36 has been described, but it is not necessarily limited to this. It is of course possible to omit one of the first concave portions 39, 39 and provide the first concave portion on either the first flange surface 35 or the second flange surface 36, or to omit one of the second concave portions 61, 71, 81 and the second concave portions 62, 72, 82 and provide the second concave portion on either the first flange surface 35 or the second flange surface 36.

[0066] In the embodiment, the case where the small pad 30 is fixed to the cavity surface 55 by the frictional force between the pin 57 provided on the first mold 51 and the small pad 30 has been described, but it is not necessarily limited to this. It is of course possible to fix the small pad 30 to the first mold 51 by other forces. Examples of other forces include magnetic force and adhesive force.

[0067] In the embodiment, the case where the small pad 30 is pressed against the first mold 51 when the molding die 50 is closed by the protrusion 58 provided on the second mold 52 has been described, but it is not necessarily limited to this. If the force by which the first mold 51 attracts the small pad 30 to the cavity surface 55 by the pin 57 or the like is greater than the force by which the flange 32 that has been elastically deformed by being attracted to the cavity surface 55 presses the cavity surface 55 due to the restoring force of the flange 32, the molding of the pad body 20 is performed with the flange 32 in an elastically deformed state, and thus the protrusion 58 can be omitted. Further, when a protrusion is provided on the small pad 30 and the protrusion of the small pad 30 is pressed by the second mold 52 when the molding die 50 is closed and the small pad 30 is pressed against the first mold 51, the protrusion 58 of the second mold 52 can be omitted.

Explanation of Reference Numerals

[0068] 10 Sheet pad 20 Pad body 30, 60, 70, 80, 90 Small pad 31 Body portion 32 Flange 33 First surface 34 Second surface 35 First flange surface 35a Edge of the first flange surface 36 Second flange surface 37 Tip surface 38, 39 First recess 40, 61, 62, 71, 72, 81, 82 Second recess 51 First mold 52 Second mold 55 Cavity surface 58 Protrusion

Claims

1. A seat pad in which a pad body made of a soft foam and a small pad made of an elastic body are integrated, wherein the small pad includes a main body portion having a first surface exposed from the pad body and a second surface in contact with the pad body, and a flange projecting from the main body portion, the flange includes a first flange surface adjacent to the first surface, a tip surface adjacent to the first flange surface and in contact with the pad body, and a second flange surface adjacent to the tip surface and the second surface and in contact with the pad body, in the small pad, the area of the flange projected onto a plane parallel to the first flange surface is smaller than the area of the main body portion projected onto the plane, and there are no recesses penetrating the flange in the thickness direction and no recesses extending along the entire edge of the first flange surface, a seat pad in which a recess is formed from the boundary between the first surface and the first flange surface toward the second flange surface, and a first recess is formed from the boundary between the second surface and the second flange surface toward the first flange surface, and the recesses are provided at the boundary between the main body portion and the flange.

2. The seat pad according to claim 1, wherein the length of the flange projecting from the main body portion of the small pad in a first direction is greater than the thickness of the flange in a second direction perpendicular to the first direction.

3. The seat pad according to claim 1 or 2, wherein the flange is provided with a second recess on at least one of the first flange surface and the second flange surface, and the first flange surface or the second flange surface is recessed.

4. The seat pad according to claim 3, wherein the second recess is provided on the first flange surface and is connected to the edge of the first flange surface.

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