Seat pad manufacturing method and small pad

Abstract

To provide a method for manufacturing a seat pad and a small pad capable of reducing a generation of abnormal noise caused by a portion where foam has wrapped around and solidified during expansion.SOLUTION: A method for manufacturing a seat pad includes: an attaching step of attaching a small pad to a cavity surface of a first die; a die closing step of closing the first die and a second die; and a molding step of integrating a pad body and the small pad by foaming a raw material liquid of the pad body between the first die and the second die. The second die has a protrusion that protrudes toward the first die when the first die and the second die are closed. In the die closing step, the protrusion is pressed against a main body of the small pad, and a flange of the small pad is pressed against the cavity surface. The small pad comprises: the main body having a first surface exposed from a soft foam, and the flange extending from the main body having a first flange surface adjacent to the first surface. The flange is inclined so that an angle between the first surface and the first flange surface is 135° or more and less than 180°.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a seat pad in which a small pad made of an elastic body and a pad body made of soft foam are integrated, and to the small pad. [Background technology]

[0002] A seat pad in which a small pad made of an elastic body and a pad main body made of soft urethane foam are integrated is known (Patent Document 1). This type of seat pad is made by fixing the small pad to the cavity surface of a first mold, and then foaming the raw material liquid of the pad main body between the first and second molds to integrate the pad main body and the small pad. If the foam that is expanding seeps into the gap that forms between the cavity surface of the first mold and the small pad, the excess foam that has solidified and surrounded the small pad may rub against the vehicle body and cause abnormal noise. The technology disclosed in Patent Document 1 involves preparing a small pad with a recess, fitting a wall on the cavity surface of the first mold into the recess of the small pad, reducing the gap between the cavity surface and the small pad and reducing the foam that is expanding. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-068336 Summary of the Invention [Problem to be solved by the invention]

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

[0005] The present invention has been made to meet this demand, and its object is to provide a method for manufacturing a seat pad and a small pad that can reduce the generation of abnormal noise caused by areas where the foam has wrapped around and solidified. [Means for solving the problem]

[0006] The seat pad comprises a pad main body made of soft foam and a small pad made of elastic material. The small pad comprises a main body portion having a first surface exposed from the pad main body and a second surface in contact with the pad main body, and a flange extending from the main body portion. The flange comprises a first flange surface adjacent to the first surface, a tip surface adjacent to the first flange surface and in contact with the pad main body, and a second flange surface adjacent to the tip surface and the second surface and in contact with the pad main body.

[0007] The method for manufacturing a seat pad of the present invention includes an attachment step of attaching a small pad to the cavity surface of a first mold, a mold closing step of closing the first mold and the second mold, and a molding step of 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. The second mold has a protrusion that protrudes toward the first mold when the first mold and the second mold are closed. In the attachment step, the small pad is attached to the first mold with at least a gap between the boundary between the main body and the flange and the cavity surface. In the mold closing step, the protrusion is pressed against the main body to reduce the gap, and the flange is pressed against the cavity surface.

[0008] The small pad of the present invention is directly used in carrying out the manufacturing method of a seat pad. The small pad is made of an elastic body and includes a main body having a first surface exposed from the flexible foam, and a flange extending from the main body and having a first flange surface adjacent to the first surface. The flange is inclined so that the angle between the first surface and the first flange surface is 135° or more and less than 180°. [Effects of the Invention]

[0009] According to the seat pad, the small pad has a flange that protrudes from the main body, so that the foam that is being expanded during manufacturing the seat pad is less likely to get around the first surface of the main body by the amount of the flange that protrudes.

[0010] According to the small pad of the present invention, the flange is inclined so that the angle between the first surface of the main body and the first flange surface of the flange is 135° or more and less than 180°. Therefore, even if the flange is deformed due to the influence of heat when it is integrated with the flexible foam in the mold, a gap is unlikely to form between the first flange surface and the mold. Since the foam is unlikely to wrap around the first flange surface during foaming, the generation of abnormal noise caused by the foam wrapping around and solidifying can be reduced.

[0011] According to the method for manufacturing a seat pad of the present invention, the flange is pressed against the cavity surface during the mold closing process, which reduces the likelihood of a gap forming between the flange and the cavity surface. This reduces the amount of foam that gets between the flange and the cavity surface during expansion, which reduces the likelihood of the foam wrapping around the first flange surface of the flange. This reduces the generation of noise caused by the foam wrapping around and solidifying in the area. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 2 is a cross-sectional view of the seat pad according to the first embodiment. [Figure 2] 1(a) is a cross-sectional view of the mold with the small pad attached, and FIG. 1(b) is a cross-sectional view of the mold when closed. [Figure 3] 3(a) is a rear view of the small pad as seen from the direction of arrow IIIa in FIG. 2, and FIG. 3(b) is a cross-sectional view of the small pad taken along line IIIb-IIIb in FIG. 3(a). [Figure 4] 4(a) is a rear view of the small pad in the second embodiment, and FIG. 4(b) is a cross-sectional view of the small pad taken along line IVb-IVb in FIG. 4(a). [Figure 5] 5(a) is a rear view of the small pad in the third embodiment, and FIG. 5(b) is a cross-sectional view of the small pad taken along line Vb-Vb in FIG. 5(a). [Figure 6] 6(a) is a rear view of the small pad in the fourth embodiment, and FIG. 6(b) is a cross-sectional view of the small pad taken along line VIb-VIb in FIG. 6(a). [Figure 7]7A is a rear view of the small pad in the fifth embodiment, FIG. 7B is a cross-sectional view of the small pad taken along line VIIb-VIIb in FIG. 7A, and FIG. 7C is a cross-sectional view of the small pad taken along line VIIc-VIIc in FIG. 7A. DETAILED DESCRIPTION OF THE INVENTION

[0013] Preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Fig. 1 is a cross-sectional view of a seat pad 10 in a first embodiment. Arrows X, Y, and Z in Fig. 1 indicate first, second, and third directions, which are orthogonal to each other, of the seat pad 10 and the small pad 30, respectively (the same applies to Figs. 2 to 7). Fig. 1 does not show the backing material and other components disposed on the seat pad 10. The seat pad 10 is formed by integrating a pad main 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 seats in 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 a seated person and is formed by a pad main body 20. A small pad 30 is disposed on a back surface 12 of the seat pad 10 opposite the surface 11 so as to be embedded in the pad main body 20. The back surface 12 of the seat pad 10 is the surface that comes into contact with the body of the vehicle (not shown). The pad main 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 main 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 porous body in which open or closed cells are dispersed in a synthetic resin. The elastic body can be any elastic body that has heat resistance and mechanical strength sufficient to withstand the heat generated during molding of the pad main body 20, and is made of a different material from the soft foam that is the material of the pad main body 20, and is not particularly limited. Examples of synthetic resins that make up the elastic body include polyolefins such as polyethylene and polypropylene, polystyrene, polyurethane, phenolic resin, and polyvinyl chloride. The elastic body may also be made of rubber or elastomer.

[0016] The elastic body constituting the small pad 30 can be appropriately selected from those having a density and hardness different from that of the soft foam. By using an elastic body with a lower density than the soft foam, the weight of the seat pad 10 can be reduced accordingly. By using an elastic body with a higher 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 with a lower density and higher hardness than the soft foam (for example, expanded polypropylene or expanded polystyrene) is embedded in the pad main body 20, the weight of the seat pad 10 can be reduced and the hardness can be increased.

[0017] The small pad 30 comprises a main body 31 and a flange 32 extending from the main body 31. The main body 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 in the pad main body 20 is connected to the second surface 34. The entire first surface 33 of the main body 31 forms a part of the back surface 12 of the seat 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 farthest from the main body portion 31 in the first direction (X direction). An edge 35a of the first flange surface 35 is located on the back surface 12 of the seat 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 and the tip surface 37 of the main body 31 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 easily bendable than when 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 31 in the second direction is greater than the thickness of the flange 32.

[0020] The small pad 30 has a first recess 38 recessed toward the second flange surface 36 at the boundary between the first surface 33 of the main body 31 and the first flange surface 35 of the flange 32. The small pad 30 has a first recess 39 recessed toward the first flange surface 35 at the boundary between the second surface 34 of the main body 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] The first recesses 38, 39 shorten the distance between the first flange surface 35 and the second flange surface 36, making it easier for the flange 32 to bend. This is particularly effective when the hardness of the small pad 30 is greater than the hardness of the pad body 20. The first recess 39 is provided between the second flange surface 36 and the second surface 34, so the contact area between the flange 32 and the pad body 20 increases by the amount of the first recess 39. This improves the bonding strength between the flange 32 and the pad body 20.

[0022] The flange 32 is formed with a second recess 40 that penetrates from the first flange surface 35 to the second flange surface 36. The pad body 20 is in contact with the second recess 40. The contact area between the flange 32 and the pad body 20 increases by the amount of the second recess 40, thereby improving the bonding strength between the flange 32 and the pad body 20. If the hardness of the small pad 30 is greater than that 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] A manufacturing method of the seat pad 10 will be described with reference to Figures 2(a) and 2(b). Figure 2(a) is a cross-sectional view of the mold 50 to which the small pads 30 are attached. Figure 2(b) is a cross-sectional view of the mold 50 when closed. In Figures 2(a) and 2(b), the illustration of the reinforcing material of the backing material placed in the mold 50 is omitted. The backing material is a nonwoven fabric or the like placed on the back surface 12 of the seat pad 10, and the reinforcing material is a hanging wire, resin clip, frame, or the like embedded in the pad main body 20.

[0024] The seat pad 10 is manufactured using a molding die 50. The molding die 50 includes a first die 51, a second die 52, and a hinge 53 that connects the first die 51 and the second die 52 so that they can be opened and closed. When the molding die 50 is closed, a cavity 54 is formed between the first die 51 and the second die 52. A portion including the back surface 12 of the seat pad 10 is molded by a cavity surface 55 of the first die 51, and a portion including the front surface 11 of the seat pad 10 is molded by a cavity surface 56 of the second die 52.

[0025] Pins 57 for attaching the small pads 30 are provided on the cavity surface 55 of the first die 51. Protrusions 58 are provided on the cavity surface 56 of the second die 52, protruding toward the cavity surface 55 of the first die 51 when the forming die 50 is closed. The protrusions 58 may be provided in multiple locations on the second die 52 depending on the size and shape of the small pads 30.

[0026] The small pad 30 attached to the first mold 51 will be described with reference to Figures 3(a) and 3(b). Figure 3(a) is a rear view of the small pad 30 as seen from the direction of arrow IIIa in Figure 2. Figure 3(b) is a cross-sectional view of the small pad 30 taken along line IIIb-IIIb in Figure 3(a). In Figures 3(a) and 3(b), part of the main body 31 is omitted (the same applies to Figures 4(a) to 7(c)).

[0027] 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 is a groove with a semicircular cross section, and is connected to the edge 35a of the first flange surface 35. The cross section of the first recess 38 is not limited to a semicircle, and may be a polygon such as a triangle or a rectangle. Similar to the first recess 38, 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 of the flange 32 in the width direction (Z direction).

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

[0029] As shown in Figure 3(b), before the small pad 30 is attached to the first mold 51, the flange 32 is inclined so that the angle θ 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 is the angle between 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. In the seat pad 10 in which the small pad 30 is integrated with the pad main body 20, the plane onto which the flange 32 and the main body 31 are projected is equal to a plane parallel to this line segment (see Figure 1).

[0030] 2(a) will be explained. In the attachment process of attaching the small pad 30 to the first die 51, the small pad 30 is fixed to the first die 51 by fitting a pin 57 into a hole 31a provided in the main body 31 so that the cavity surface 55 of the first die 51 faces the first surface 33 of the main body 31 of the small pad 30 and the first flange surface 35 of the flange 32. When the small pad 30 is fixed to the first die 51, a gap 59 may be present between the base of the flange 32 and the cavity surface 55.

[0031] After the raw material liquid for the flexible urethane foam is mixed and supplied to the second mold 52 from an injection device (not shown), the molding mold 50 is closed in the mold closing step as shown in Figure 2(b). The position and length of the protrusion 58 are set so that the main body 31 of the small pad 30 is pressed against the first mold 51 when the molding mold 50 is closed. As the mold is closed, the protrusion 58 presses the small pad 30 against the first mold 51. If there is a gap 59 in the attachment step, the gap 59 will disappear or become smaller in the mold closing step.

[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 of the protrusions 58 pressing against the main body 31. The small pad 30 is made of an elastic body, and the first flange surface 35 of the flange 32 is inclined relative to the first surface 33 of the main body 31. Therefore, 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 is elastically deformed (bent). In addition to the force of the protrusions 58 pressing against the main body 31, the first flange surface 35 of the flange 32 presses strongly against the cavity surface 55 due to the restoring force of the elastic deformation of the flange 32.

[0033] In the small pad 30, the angle θ between the first surface 33 of the main body 31 and the first flange surface 35 of the flange 32 is equal to or greater than 135° and less than 180°, so that 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, although this depends on the shape of the cavity surface 55. To prevent damage to the flange 32, the angle θ is more preferably equal to or greater than 165° and less than 178°.

[0034] The raw material liquid supplied to the second mold 52 foams and, in the molding process, fills the cavity 54 while coming into contact with the second surface 34, second flange surface 36, and tip surface 37 of the small pad 30, to form the pad main body 20 with holes 13 at the portions of the protrusions 58. The first flange surface 35 of the flange 32 is pressed against the cavity surface 55 by the force of the protrusions 58 pressing against the main body portion 31 plus the restoring force of the flange 32. Therefore, gaps into which the foam can penetrate during foaming are unlikely to form between the first flange surface 35 and the cavity surface 55. Therefore, the foam that has penetrated into the gaps is unlikely to solidify on the first flange surface 35.

[0035] Although it depends on the material and shape of the small pad 30, the temperature of the mold 50 during the molding process and the heat generated by the reaction of the raw material liquid may cause deformation near the edge 33a of the first surface 33 of the small pad 30, causing the edge 33a to warp and create a gap between the edge 33a and the cavity surface 55. If the foam that is expanding fills this gap and solidifies, the solidified part may rub against the vehicle body, causing abnormal noise.

[0036] To reduce the occurrence of this foam wrapping around, it is preferable to provide a flange 32 that protrudes from the main body 31 in 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, the restoring force of the flange 32 makes it difficult for a gap to form between the edge 35a of the first flange surface 35 and the cavity surface 55. Therefore, it is sufficient to selectively provide the flange 32 in a location on the first surface 33 of the main body 31 where warping is likely to occur. The flange 32 may also be provided around the entire periphery of the edge 33a of the first surface 33 of the main body 31.

[0037] Because the length (dimension in the X direction) of the flange 32 is greater than the thickness (dimension in the Y direction) of the flange 32, the flange 32 can be easily deformed to conform to the shape of the cavity surface 55 during the mold closing process. Furthermore, because the small pad 30 is provided with the first recesses 38, 39 and the second recess 40, the flange 32 can be easily deformed to conform to the shape of the cavity surface 55. Because a plurality of second recesses 40 are provided at intervals in the width direction of the flange 32, deformation due to bending or twisting in the width direction (Z direction) of the flange 32 can easily occur, making it even easier to deform the flange 32 to conform to the shape of the cavity surface 55.

[0038] The seat pad 10 has a small pad 30 embedded in a pad main body 20 made of soft foam. The small pad 30 has a flange 32 that protrudes from the main body 31, making it more difficult for the foam to reach the first surface 33 of the main body 31. The area of ​​the flange 32 of the small pad 30 projected onto a plane parallel to the first flange surface 35 is smaller than the area of ​​the main body 31 projected onto that plane, so when a person uses the seat pad 10 and a force is applied to the pad main body 20 approximately 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 that abnormal noise will occur due to the solidified portion where the foam has wrapped around, so even if the foam wraps around the first flange surface 35, it is possible to reduce abnormal noise caused by the portion where the foam has wrapped around and solidified on the first flange surface 35 rubbing against the body of the vehicle.

[0039] A second embodiment will be described with reference to Figures 4(a) and 4(b). In the first embodiment, a case where a second recess 40 penetrating the flange 32 in the thickness direction is provided in the flange 32 is described. In the second embodiment, a case where second recesses 61, 62 consisting of recesses that do not penetrate the flange 32 is provided in the flange 32 is described. The same parts as those described in the first embodiment are given the same reference numerals, 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 in Fig. 4(a). Like the small pad 30, the small pad 60 is integrated with the pad body 20 to form the seat pad 10.

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

[0042] The presence of the second recesses 61, 62 in the first flange surface 35 and the second flange surface 36 of the small pad 60 makes the flange 32 easier to bend. Therefore, when attaching the small pad 60 to the first mold 51, the flange 32 can be easily deformed to conform to the shape of the cavity surface 55. The contact area between the pad main body 20 and the second flange surface 36 is increased by the amount of the second recesses 62, thereby improving the bonding strength between the flange 32 and the pad main body 20. Furthermore, the second recesses 61, 62 do not penetrate the flange 32, and the second recess 61 is not connected to the edge 35a of the first flange surface 35, so that the flexible foam can be prevented from entering the first flange surface 35 from the second recesses 61, 62.

[0043] A third embodiment will be described with reference to Figures 5(a) and 5(b). In the second embodiment, a case was described in which second recesses 61, 62 are provided at an interval in the width direction (Z direction) of the flange 32. In the third embodiment, a case will be described in which second recesses 71, 72 extending in the width direction of the flange 32 are provided in the flange 32. The same parts as those described in the first embodiment are given the same reference numerals, 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 in Fig. 5(a). Like the small pad 30, the small pad 70 is integrated with the pad body 20 to form the seat pad 10.

[0045] The small pad 70 has a second recess 71 recessed toward the second flange surface 36 on the first flange surface 35 of the flange 32 (one location in this embodiment). 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 has a second recess 72 recessed toward the first flange surface 35 on the second flange surface 36 of the flange 32 (one location in this embodiment). 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] The second recesses 71, 72 on the first flange surface 35 and the second flange surface 36 of the small pad 70 make it easier for the flange 32 to bend. Therefore, when the small pad 70 is attached to the first mold 51, the flange 32 can be easily deformed to conform to the shape of the cavity surface 55. The contact area between the pad main body 20 and the second flange surface 36 increases by the amount of the second recesses 72, improving the bonding strength between the flange 32 and the pad main body 20.

[0047] A fourth embodiment will be described with reference to Figures 6(a) and 6(b). In the third embodiment, a case where second recesses 71, 72 extending in the width direction (Z direction) of the flange 32 are provided in the flange 32 will be described. In the fourth embodiment, a case where second recesses 81, 82 extending in the length direction (X direction) of the flange 32 will be described. The same parts as those described in the first embodiment will be assigned the same reference numerals, 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 in Fig. 6(a). The small pad 80, like the small pad 30, is integrated with the pad body 20 to form the seat pad 10.

[0049] The small pad 80 has second recesses 81 recessed toward the second flange surface 36 at multiple locations (three locations in this embodiment) on the first flange surface 35 of the flange 32. The second recesses 81 extend in the length direction of the flange 32 from an edge 35a of the first flange surface 35 where the tip surface 37 of the flange 32 and the first flange surface 35 intersect toward the main body 31. The second recesses 81 are separated from the first recesses 38.

[0050] The small pad 80 has second recesses 82 recessed toward the first flange surface 35 at multiple locations (three locations in this embodiment) on the second flange surface 36 of the flange 32. The second recesses 82 extend in the length direction of the flange 32 from an edge of the second flange surface 36 where the tip surface 37 of the flange 32 and the second flange surface 36 intersect toward the main body 31. The second recesses 82 are separated from the first recesses 39.

[0051] The second recesses 81, 82 on the first flange surface 35 and the second flange surface 36 of the small pad 80 make it easier for the flange 32 to bend. Therefore, when the small pad 80 is attached to the first mold 51, the flange 32 can be easily deformed to conform to the shape of the cavity surface 55. The contact area between the pad main body 20 and the second flange surface 36 increases by the amount of the second recesses 82, improving the bonding strength between the flange 32 and the pad main body 20.

[0052] If the foam penetrates into the second recess 81, the contact area between the pad main body 20 and the first flange surface 35 increases by the amount of the second recess 81, thereby improving the bonding strength between the flange 32 and the pad main body 20. If only a small amount of foam penetrates into the second recess 81, the gas generated when the raw material liquid foams and reacts and the air remaining in the molding die 50 can be stored in the second recess 81. This reduces underfill of the soft foam that is likely to occur between the tip surface 37 of the small pad 80 and the pad main body 20 due to remaining gas.

[0053] A fifth embodiment will be described with reference to Figures 7(a), 7(b), and 7(c). In the third embodiment, a case was described in which second recesses 71, 72 extending in the width direction (Z direction) of the flange 32 are provided in the flange 32. In the fourth embodiment, a case was described in which second recesses 81, 82 extending in the length direction (X direction) of the flange 32 are provided in the flange 32. In the fifth embodiment, a case will be described in which second recesses 71, 72, 81, 82 are provided in the flange 32. The same parts as those described in the first embodiment are 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 in Fig. 7(a). The small pad 90, like the small pad 30, is integrated with the pad body 20 to form the seat pad 10.

[0055] The small pad 90 has second recesses 71 and 81 formed on the first flange surface 35, and second recesses 72 and 82 formed on 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 even easier to bend. Therefore, when the small pad 90 is attached to the first mold 51, the flange 32 can be more easily deformed to conform to the shape of the cavity surface 55.

[0056] The contact area between the pad main body 20 and the second flange surface 36 increases by the amount of the second recesses 72, 82, thereby improving the bonding strength between the flange 32 and the pad main body 20. Furthermore, the contact area between the pad main body 20 and the first flange surface 35 increases by the amount of the second recesses 71, 81, thereby improving the bonding strength between the flange 32 and the pad main body 20. Furthermore, as in the fourth embodiment, the second recesses 81 can reduce underfill of the flexible foam.

[0057] The present invention has been described above based on the embodiments, but the present invention is not limited to the above embodiments, and it can be easily inferred that various improvements and modifications are possible within the scope of the present invention.

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

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

[0060] In the embodiment, the cavity surface 55 of the first mold 51 is generally flat, but this is not limited to this. It is of course possible to provide a curved surface or a step 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 backing material (not shown) is provided to be placed on the seat pad 10 and the mold 50, but the present invention is not limited to this. The backing material may not be provided.

[0062] In the embodiment, the small pad with the flange 32 extending from a portion of the circumference of the main body 31 has been described, but the present invention is not limited to this. The flange 32 may be provided at multiple locations around the circumference of the main body 31, or may be provided around the entire circumference of the main body 31.

[0063] In the embodiment, the first recess 38 and the second recess 71 of the flange 32 are described as being provided continuously across the entire width of the first flange surface 35, but this is not necessarily limited to this. It is of course possible to provide the first recess 38 and the second recess 71 discontinuously across the entire width of the first flange surface 35, or to provide the first recess 38 and the second recess 71 in a portion of the width of the first flange surface 35.

[0064] In the embodiment, the first recesses 39 and the second recesses 72 of the flange 32 are described as being provided continuously across the entire width of the second flange surface 36, but this is not necessarily limited to this. It is of course possible to provide the first recesses 39 and the second recesses 72 discontinuously across the entire width of the second flange surface 36, or to provide the first recesses 39 and the second recesses 72 in a portion of the width of the second flange surface 36. It is of course possible to bend the first recesses 38, 39 and the second recesses 71, 72 or change the width or depth depending on the shapes of the main body 31 and the flange 32.

[0065] In the embodiment, a case has been described in which the first recess 39 is provided on the second flange surface 36 when the first recess 38 is provided on the first flange surface 35, and the second recess 62, 72, 82 is provided on the second flange surface 36 when the second recess 61, 71, 81 is provided on the first flange surface 35, but this is not necessarily limited to this. It is of course possible to omit one of the first recesses 39, 39 and provide the first recess on either the first flange surface 35 or the second flange surface 36, or to omit one of the second recesses 61, 71, 81 and the second recess 62, 72, 82 and provide the second recess 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 die 51 and the small pad 30 has been described, but this is not necessarily limited to this. It is of course possible to fix the small pad 30 to the first die 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 die 51 by the protrusion 58 provided on the second die 52 when the molding die 50 is closed has been described, but this is not necessarily limited to this. If the force with which the first die 51 attracts the small pad 30 to the cavity surface 55 by the pin 57 or the like is greater than the force with which the flange 32 presses against the cavity surface 55 due to the restoring force of the flange 32, which has been elastically deformed by being attracted to the cavity surface 55, then the pad body 20 is molded with the flange 32 elastically deformed, and the protrusion 58 can be omitted. Also, if a protrusion is provided on the small pad 30, and the protrusion of the small pad 30 is pressed by the second die 52 when the molding die 50 is closed, and the small pad 30 is pressed against the first die 51, the protrusion 58 of the second die 52 can be omitted. [Explanation of symbols]

[0068] 10 seat pad 20 Pad body 30,60,70,80,90 small pads 31 Main body 32 Tsuba 33 Page 1 34 2nd page 35 1st Tsuba-men 35a Edge of the first tsuba surface 36 Second Tsuba-men 37 Tip surface 38,39 First recess 40, 61, 62, 71, 72, 81, 82 Second recess 51 Type 1 52 Type 2 55 Cavity surface 58 Protrusion

Claims

1. A method for manufacturing a seat pad, which integrates a small pad made of an elastic body having a main body and a flange extending from the main body, and a pad main body made of soft foam, a mounting step of mounting the small pad on the cavity surface of a first mold; a mold closing step of closing the first mold and the second mold; a molding step of 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 pads, the second mold includes a protrusion that protrudes toward the first mold when the first mold and the second mold are closed, a gap is formed between the base of the flange of the small pad attached to the first mold in the attaching step and the cavity surface; In the mold closing step, the protrusion is pressed against the main body portion, and the flange is pressed against the cavity surface, thereby eliminating or reducing the gap.

2. The small pad includes a main body having a first surface exposed from the flexible foam; a flange having a first flange surface adjacent to the first surface and extending from the main body portion; The method for manufacturing a seat pad according to claim 1, wherein the flange is inclined so that an angle formed between the first surface and the first flange surface is equal to or greater than 135° and less than 180°.

3. A small pad made of an elastic body integrated with a flexible foam and pressed against the cavity surface of the first mold, a main body having a first surface exposed from the flexible foam; and a flange having a first flange surface adjacent to the first surface and extending from the main body; the flange is inclined so that the angle between the first surface and the first flange surface is equal to or greater than 135° and less than 180°, The angle formed between the first surface and the first flange surface is such that, when the first surface and the first flange surface are pressed against the cavity surface, the flange is elastically deformed and becomes larger.

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