Air-conditioned seat pad structure

Abstract

To provide a pad structure of an air-conditioning seat, capable of suppressing an increase in manufacturing man hours and costs, and reducing the occurrence of molding failure due to accumulation of gas.SOLUTION: A blowing part 40 and a reinforcement surface material 46 are provided in a rear face of a cushion pad 4A of an air-conditioning seat. A plurality of flow channels 42a-42i, and projections 45a-45d positioned between the respective flow channels 42a-42i are formed in the blowing part 40. The reinforcement surface material 46 has a base part 46a for covering a part positioned outside the blowing part 40 in the rear face of the cushion pad 4A, and a first extension part 46b extending from the base part 46a to the first flow channel 42a positioned between the projections 45a-45d and the base part 46a. The first extension part 46b covers a side wall part positioned at a base part 46a side of the first flow channel 42a, and a bottom wall part of the first flow channel 42a, and the tip part reaches a side wall part positioned at the projections 45a-45d side of the first flow channel 42a.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a pad structure for an air-conditioned seat for a vehicle. [Background technology]

[0002] Air-conditioned seats are known that are installed in seats in vehicles such as automobiles, and that have air conditioning devices such as blower fans, and that have air-blowing grooves formed in the pads that make up the seat and backrest, and that send air to the seat surface through the grooves or suck air from the seat surface, thereby improving the comfort of seated occupants (see, for example, Patent Document 1).

[0003] The cushion pad for an air-conditioned vehicle seat pad described in Patent Document 1 consists of a pad body and a loading body fitted into a recess that is recessed upward from the bottom surface of the pad body. The pad body has a hole that penetrates from the seat surface to the ceiling surface of the recess, and the loading body has grooves on the top and side surfaces for air circulation.

[0004] To mold the charge body, a lower mold is used, which has a protrusion on the bottom of the cavity that extends from one end to the other. This lower mold is tilted so that the bottom of the cavity slopes downward from one end to the other. After the urethane liquid is supplied to the one end, the mold is closed and the charge body is foam-molded. This allows the urethane liquid to flow smoothly down the bottom of the cavity, preventing air pockets from forming in the corners of the cavity. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-200942 Summary of the Invention [Problem to be solved by the invention]

[0006] However, in the cushion pad structure described in Patent Document 1, the loading body in which the air circulation grooves are formed must be molded separately from the pad body, which increases the number of manufacturing steps and costs. Also, gas generated by foaming of the urethane liquid is not discharged to the outside of the mold but remains in the cavity, which can cause molding defects (underfill) due to gas accumulation, leaving room for improvement.

[0007] The present invention has been made in consideration of the above-described situation, and its purpose is to provide a pad structure for an air-conditioning seat that can suppress increases in manufacturing labor and costs and reduce the occurrence of molding defects due to gas accumulation. [Means for solving the problem]

[0008] In order to solve the problems of the above-mentioned conventional art, the present invention provides an air-conditioning seat pad structure comprising: an air-blowing section in which a plurality of groove-shaped flow paths recessed toward the surface side are formed on the back surface of a pad of an air-conditioning seat for a vehicle; openings penetrating from the bottom wall portions of the plurality of flow paths to the surface of the pad; a reinforcing surface material provided on the back surface of the pad and made of a breathable material; and protrusions formed within the air-blowing section of the pad, protruding toward the back surface of the pad from the bottom wall portions of the plurality of flow paths and positioned between each of the flow paths, wherein the plurality of flow paths, the air-blowing section, the openings, and the protrusions of the pad are foam-formed as a single unit, and the reinforcing surface material has: a base portion covering a portion of the back surface of the pad that is positioned outside the air-blowing section; and a first extension portion extending from the base portion toward a first flow path that is positioned between the protrusions and the base portion of the plurality of flow paths of the air-blowing section, the first extension portion covering a side wall portion that is positioned on the base portion side of the first flow path and the bottom wall portion of the first flow path, and whose tip portion reaches a side wall portion that is positioned on the protrusion side of the first flow path. In this air-conditioning seat pad structure, the pad is a cushion pad that constitutes the seat portion of the air-conditioning seat, and the back surface of the cushion pad is fixed to a cushion frame that supports the cushion pad. The protrusion extends in the width direction of the cushion frame. And has a closed cross-section structureand the cushion pad is provided at a position on the rear surface of the cushion pad that overlaps with the cross member in a plan view of the cushion frame from below. The protrusion is surrounded by the plurality of flow paths. The plurality of flow paths include a second flow path extending in a direction intersecting the first flow path, and a third flow path extending in a direction intersecting the second flow path at a position sandwiching the protrusion between the first flow path and the third flow path. The protrusion has an enclosing portion that is in contact with and surrounded by each of the side wall portions of the first flow path, the second flow path, and the third flow path. The reinforcing surface material extends from the first extension portion toward the top surface of the protrusion, and is in contact with the side wall portion located on the protrusion side of the first flow path. The entire top surface of the protrusion, including the surrounding portion and a second extension portion covering the The second extension portion is configured to overlap the cross member in the plan view. [Effects of the Invention]

[0009] According to the pad structure of the air-conditioning seat of the present invention as described above, cushion Since a blower with multiple flow paths is formed on the back surface of the pad, there is no need to mold the pad body and the loading body separately as in the conventional structure. cushion The pad and each airflow passage can be integrally molded, which can suppress increases in manufacturing steps and costs. In addition, the breathable reinforcing surface material has a base portion and a first extension portion extending from the base portion toward the first passage. , and a second extension portion extending from the first extension portion toward the top surface of the protrusion. The first 、2 The extension creates the first flow path and the top surface of at least the surrounding portion of the protrusion. Because it is covered, cushion During foam molding of the pad, foaming gases etc. that gather in the corresponding parts of the protrusions in the cavity of the mold are absorbed by the first 、2 Dispersed and absorbed within the extension and base portions, and / or 、2 The gas is then discharged to the outside of the mold through the extension and base, which reduces the occurrence of molding defects caused by gas accumulation during foam molding. Furthermore, when the cushion pad is deflected downward of the vehicle due to a load acting on it from above, the protrusion comes into contact with and is supported by the cross member below, preventing the cushion pad from sinking too far. Also, by suppressing deformation of the cushion pad, the cross-sectional area of ​​each flow path formed in the air blower section is ensured, preventing a decrease in air conditioning performance. [Brief explanation of the drawings]

[0010] [Figure 1]1 is a perspective view showing a schematic configuration of an air-conditioning seat to which a pad structure according to the present invention is applied; [Figure 2] FIG. 2 is a perspective view of the cushion pad of the first embodiment as viewed from the front surface side. [Figure 3] FIG. 2 is a perspective view of the cushion pad of the first embodiment as viewed from the back surface side. [Figure 4] 4 is an enlarged perspective view of the periphery of the blower unit in FIG. 3. FIG. [Figure 5] 4 is an enlarged plan view showing the periphery of the blower unit in FIG. 3. FIG. [Figure 6] 4 is a cross-sectional view of the cushion pad and the foam molding die of the first embodiment taken along line AA in FIG. 3. [Figure 7] 3A to 3C are diagrams illustrating the foam molding process of the cushion pad of the first embodiment. [Figure 8] FIG. 11 is a perspective view of the periphery of the air blowing section of the cushion pad of the second embodiment, as viewed from the back side. [Figure 9] FIG. 10 is a cross-sectional view of a cushion pad and a foam molding mold according to a second embodiment. [Figure 10] FIG. 10 is a cross-sectional view of a cushion pad and a cushion frame according to a third embodiment. [Figure 11] FIG. 11 is a plan view of a cushion pad and a cushion frame according to a third embodiment, as viewed from below the vehicle. [Figure 12] FIG. 11 is a perspective view of the periphery of the air blowing section of the cushion pad of the fourth embodiment, as viewed from the back surface side. [Figure 13] FIG. 10 is a perspective view of the back pad according to the application example, seen from the rear surface side. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention will be described in detail below based on the illustrated embodiments. [Air-conditioning seat structure] 1 is a perspective view showing a schematic configuration of an air-conditioned seat to which the pad structure according to the present invention is applied. In the drawing, the arrow Fr direction indicates the front of the vehicle (air-conditioned seat) in the longitudinal direction, the arrow O direction indicates the outside of the vehicle in the width direction of the vehicle, and the arrow U direction indicates the top of the vehicle in the vertical direction of the vehicle.

[0012] In Fig. 1, the air-conditioned seat 1 includes a seat cushion 2 constituting the seat portion, a seat back 3 constituting the backrest, and a seat covering (not shown) that is installed to cover the seat cushion 2 and the seat back 3. The seat cushion 2 includes a cushion pad 4 foam-molded using a urethane material, and a cushion frame 5 that supports the cushion pad 4. A plurality of openings 41, 43a for blowing air are formed in the front portion of the surface (seating surface) of the cushion pad 4 in the longitudinal direction of the vehicle. An air-conditioning device (e.g., a blower fan) (not shown) is installed in the front portion of the cushion frame 5 in the longitudinal direction of the vehicle, in the central portion in the transverse direction of the vehicle.

[0013] Like the seat cushion 2, the seat back 3 has a back pad 6 foam-molded using a urethane material, and a back frame 7 that supports the back pad 6. A plurality of openings 61 for ventilation are formed in the center of the vehicle in the vertical direction on the surface (backrest surface) of the back pad 6. An air conditioning unit (not shown) is installed in the center of the vehicle width direction at the top of the back frame 7 in the vertical direction.

[0014] [First embodiment] Figures 2 and 3 show the appearance of a cushion pad to which the pad structure according to the first embodiment of the present invention is applied, with Figure 2 being a perspective view seen from the front side and Figure 3 being a perspective view seen from the back side. Also, Figures 4 and 5 show an enlarged view of the periphery of the blower unit in Figure 3, with Figure 4 being a perspective view seen from the back side and Figure 5 being a plan view seen from the back side.

[0015] As shown in FIGS. 2 to 5, a blower 40 is provided on the rear surface of the cushion pad 4A of the first embodiment at a front portion in the vehicle longitudinal direction. A plurality of (here, nine, for example) groove-shaped flow paths 42a to 42i are formed inside the blower 40 and recessed into the surface side of the cushion pad 4A. In the first embodiment, a first flow path 42a, a third flow path 42c, a fourth flow path 42d, and a fifth flow path 42e are formed as flow paths extending in the vehicle width direction (hereinafter referred to as "width-direction flow paths"). In addition, a second flow path 42b, a sixth flow path 42f, a seventh flow path 42g, an eighth flow path 42h, and a ninth flow path 42i are formed as flow paths extending in the vehicle longitudinal direction (hereinafter referred to as "longitudinal flow paths").

[0016] The aforementioned plurality of openings 41 of the cushion pad 4A are arranged, for example, at both end portions of the sixth to ninth flow paths 42f to 42i and on extension lines of the respective flow paths 42f to 42i. Each opening 41 is formed so as to penetrate from the bottom wall portion of the corresponding flow path to the surface of the cushion pad 4A.

[0017] A central protrusion 43 that is formed to protrude toward the rear surface of the cushion pad 4A is provided in a central portion of the blower section 40 on the vehicle front side in the vehicle width direction. The fourth flow path 42d and the fifth flow path 42e extend in the vehicle width direction, sandwiching the central protrusion 43 therebetween. In other words, a width-direction flow path (the fourth flow path 42d and the fifth flow path 42e) that is divided into two parts by the central protrusion 43 is formed at the end of the blower section 40 on the vehicle front side. In addition, an opening 43a is formed in the central protrusion 43, penetrating from the top surface to the surface of the cushion pad 4A. This opening 43a is connected to the third flow path 42c via a narrow groove 43b formed in the top surface of the central protrusion 43.

[0018] The third flow path 42c is located on the vehicle rear side of the central protrusion 43 and extends in the vehicle width direction. Both end portions of the third flow path 42c are formed in positions overlapping with portions of the fourth flow path 42d and the fifth flow path 42e in the vehicle width direction. The bottom wall portion of the third flow path 42c is inclined toward the rear of the vehicle toward the back surface of the cushion pad 4A. The bottom wall portions of the fourth flow path 42d and the fifth flow path 42e are located closer to the surface of the cushion pad 4A than the bottom wall portion of the third flow path 42c. In other words, the third flow path 42c, the fourth flow path 42d, and the fifth flow path 42e are formed at different levels. A connecting portion 44 is formed adjacent to the central protrusion 43 between the third flow path 42c and the fourth flow path 42d and the fifth flow path 42e, and this connecting portion 44 connects the third flow path 42c, the fourth flow path 42d, and the fifth flow path 42e so as to be able to blow air.

[0019] A second flow path 42b is formed on the vehicle rear side of the third flow path 42c. The second flow path 42b extends from the center of the third flow path 42c in the vehicle width direction toward the vehicle rear, and its tip portion (rear end portion) intersects with the first flow path 42a. The first flow path 42a is located at the end portion on the vehicle rear side within the blower section 40, and extends across the blower section 40 in the vehicle width direction.

[0020] The width of the first flow passage 42a, i.e., the distance between the opposing sidewall portions of the first flow passage 42a, is the narrowest among the width-direction flow passages. Here, the width of each width-direction flow passage is formed so that it increases toward the front of the vehicle. Specifically, the relative widths of the first flow passage 42a, the third flow passage 42c, the fourth flow passage 42d, and the fifth flow passage 42e, which are width-direction flow passages, are first flow passage < third flow passage < fourth flow passage = fifth flow passage. However, the relative widths of the width-direction flow passages are not limited to this.

[0021] A sixth flow path 42f and an eighth flow path 42h, which are vertical flow paths, are formed between the first flow path 42a and the fourth flow path 42d. In addition, a seventh flow path 42g and a ninth flow path 42i, which are vertical flow paths, are formed between the first flow path 42a and the fifth flow path 42e.

[0022] The sixth flow path 42f is located outboard of the second flow path 42b in the vehicle width direction, and extends in the vehicle front-rear direction with the first protruding portion 45a sandwiched between the second flow path 42b and the third flow path 42c. Both ends of the sixth flow path 42f intersect with the first flow path 42a and the fourth flow path 42d.

[0023] The first protrusion 45a protrudes toward the back surface of the cushion pad 4A relative to the bottom wall portions of the adjacent flow paths 42a to 42d, 42f and is positioned between the flow paths 42a to 42d, 42f. Specifically, the top surface of the first protrusion 45a is positioned at approximately the same height as the back surface of the cushion pad 4A. Furthermore, the side surfaces of the first protrusion 45a are formed by the side wall portions of the flow paths 42a to 42d, 42f that surround the first protrusion 45a. In other words, the first protrusion 45a constitutes a partition wall between the flow paths 42a to 42d, 42f. Furthermore, the top surface of the first protrusion 45a is formed in a substantially L-shape with a protrusion that protrudes toward the center in the vehicle width direction (toward the second flow path 42b) in a plan view seen from the back surface side of the cushion pad 4A. The protrusions on the top surface of the first protrusion 45a are in contact with and surrounded by the side walls of the first to third flow paths 42a to 42c, and are arranged so that a part of them overlaps with the central protrusion 43 in the vehicle width direction.

[0024] The seventh flow path 42g is located inside (toward the center) the second flow path 42b in the vehicle width direction, and extends in the vehicle front-rear direction with the second protruding portion 45b sandwiched between the second flow path 42b and the third flow path 42c. Both ends of the seventh flow path 42g intersect with the first flow path 42a and the fifth flow path 42e.

[0025] The second protrusion 45b protrudes toward the back surface of the cushion pad 4A relative to the bottom wall portions of the adjacent flow paths 42a to 42c, 42e, and 42g and is positioned between the flow paths 42a to 42c, 42e, and 42g. Specifically, the top surface of the second protrusion 45b is positioned at approximately the same height as the back surface of the cushion pad 4A. Furthermore, the side surfaces of the second protrusion 45b are formed by the side wall portions of the flow paths 42a to 42c, 42e, and 42g that surround the second protrusion 45b. In other words, the second protrusion 45b constitutes a partition wall between the flow paths 42a to 42c, 42e, and 42g. Furthermore, the second protrusion 45b is formed in a substantially L-shape with a protrusion that protrudes outward in the vehicle width direction (toward the second flow path 42b) in a plan view seen from the back surface side of the cushion pad 4A. The second protrusion 45b is surrounded by and in contact with the side walls of the first to third flow paths 42a to 42c, and is disposed so that a portion of the second protrusion 45b overlaps with the central protrusion 43 in the vehicle width direction.

[0026] The eighth flow passage 42h is located outboard of the sixth flow passage 42f in the vehicle width direction and extends in the vehicle front-rear direction with the third protrusion 45c sandwiched between it and the sixth flow passage 42f. Both ends of the eighth flow passage 42h intersect with the first flow passage 42a and the fourth flow passage 42d. The ninth flow passage 42i is located inboard (toward the center) of the seventh flow passage 42g in the vehicle width direction and extends in the vehicle front-rear direction with the fourth protrusion 45d sandwiched between it and the seventh flow passage 42g. Both ends of the ninth flow passage 42i intersect with the first flow passage 42a and the fifth flow passage 42e. The second flow passage 42b and the sixth to ninth flow passages 42f to 42i, which are longitudinal flow passages, are formed to have approximately the same width.

[0027] A reinforcing surface material 46 made of a breathable material such as felt is provided on the back surface of the cushion pad 4A on which the first to ninth flow paths 42a to 42i and the air blower 40 having the central protrusion 43 and the first to fourth protrusions 45a to 45d are formed. The thick lines shown in FIGS. 3 to 5 correspond to the inner peripheral edge (cutout portion) of the reinforcing surface material 46. In the first embodiment, the reinforcing surface material 46 has a base portion 46a and a first extension portion 46b.

[0028] The base portion 46a of the reinforcing surface material 46 covers a portion of the back surface of the cushion pad 4A that is located outside the air blower 40. Specifically, the inner peripheral edge of the base portion 46a is formed to surround the outsides of the first flow path 42a, the fourth flow path 42d, the fifth flow path 42e, the eighth flow path 42h, and the ninth flow path 42i, which are arranged on the outer peripheral edge of the air blower 40. The outer peripheral edge of the base portion 46a is formed along the outer edge of the back surface of the cushion pad 4A. As a result, the base portion 46a of the reinforcing surface material 46 covers the entire back surface of the cushion pad 4A except for the air blower 40.

[0029] The first extension portion 46b of the reinforcing surface material 46 extends from the base portion 46a toward the first flow path 42a and covers the side wall portion of the first flow path 42a located on the base portion 46a side and the bottom wall portion of the first flow path 42a. The tip portion of the first extension portion 46b covering the bottom wall portion of the first flow path 42a reaches the side wall portion of the first flow path 42a located on the first to fourth protrusions 45a to 45d side. In other words, the first extension portion 46b is connected to a portion of the inner periphery of the base portion 46a adjacent to the first flow path 42a and is formed across the side wall portion and bottom wall portion of the first flow path 42a on the base portion 46a side. Therefore, the reinforcing surface material 46 is configured so that the base portion 46a and the first extension portion 46b continuing from the base portion 46a cover the back surface of the cushion pad 4A and the side wall portion and bottom wall portion of the first flow path 42a on the base portion 46a side.

[0030] [Foam molding of cushion pads] Next, foam molding of the cushion pad 4A of the first embodiment will be described in detail. Fig. 6 is a cross-sectional view of the cushion pad 4A and a mold for foam molding it, taken along line AA in Fig. 3. Fig. 7 is a diagram schematically illustrating the foam molding process of the cushion pad 4A.

[0031] The cushion pad 4 (4A) of the air-conditioned seat 1 as shown in Fig. 1 has a shape in which the front end portion in the vehicle front-rear direction is thick in the vehicle up-down direction and the rear end portion is thin in the vehicle up-down direction. When such a cushion pad 4A is manufactured by foam molding of a urethane material, as shown in Fig. 6, the front side of the cushion pad 4A is formed by a lower mold 101 in a molding mold 100, and the back side of the cushion pad 4A is formed by an upper mold 102. Furthermore, the mold 100 is positioned in an orientation in which the rear end portion of the cushion pad 4A is higher than the front end portion.

[0032] Generally, when foam molding is performed using a urethane material, gas generated by foaming tends to accumulate in the corners of the mold recesses. Such gas accumulation can prevent the urethane material from reaching every corner of the mold, potentially resulting in molding defects (underfill). In the mold 100 used to foam mold the cushion pad 4A of the first embodiment, the portions corresponding to the protruding portions 45a to 45d formed to separate the flow paths 42a to 42i are isolated, making it easy for gas generated by foaming to accumulate in these isolated portions. Specifically, in the cross-sectional view of FIG. 6 , gas tends to accumulate in the corners (dotted line portion B) of the recess of the upper mold 102 corresponding to the first protruding portion 45a of the cushion pad 4A, potentially resulting in underfill in the first protruding portion 45a. This also applies to the second to fourth protruding portions 45b to 45d.

[0033] In the first embodiment, to prevent the gas accumulation, the reinforcing surface material 46 provided on the back surface of the cushion pad 4A has a first extension portion 46b extending from the base portion 46a into the groove of the first flow path 42a. This first extension portion 46b covers the side wall and bottom wall of the first flow path 42a on the base portion 46a side, and its tip portion reaches the side wall on each of the protrusions 45a to 45d side. Therefore, foaming gas and the like that collects in the recesses of the upper mold 102 corresponding to each of the protrusions 45a to 45d can pass through the first extension portion 46b and the base portion 46a of the reinforcing surface material 46 in this order and further through the gap C created by the reinforcing surface material 46 between the lower mold 101 and the upper mold 102. As a result, the foaming gas and the like are dispersed and absorbed within the reinforcing surface material 46 and / or passed through the gap C to be discharged to the outside of the mold 100.

[0034] Specifically, the foam molding process of the cushion pad 4A will be briefly explained with reference to Fig. 7. The reinforcing surface material 46 is prepared in advance by cutting felt or the like to fit the shapes of the base portion 46a and the first extension portion 46b. Then, as shown in the upper part of Fig. 7, the prepared reinforcing surface material 46 is set in a predetermined position in the upper mold 102 of the mold 100, and the urethane material M is poured into the portions of the lower mold 101 that correspond to the front end and center of the seat portion of the cushion pad 4A (the lower side portion and the middle side portion), and the mold is closed.

[0035] Once the mold clamping is complete, the process moves to the step of foaming the urethane material M, as shown in the middle of Figure 7. The arrows in the figure indicate the flow of the urethane material M that fills the space between the lower mold 101 and the upper mold 102 as it foams. The urethane material M fills toward the back surface and rear end of the cushion pad 4A. With respect to the filling direction of the urethane material M, the first extension portion 46b of the reinforcing surface material 46 extends from the inner peripheral edge of the base portion 46a located downstream toward the first flow path 42a located upstream.

[0036] As described above, gases and the like generated during the foaming process are collected in the recesses of the upper mold 102 that correspond to the protruding portions 45a to 45d of the cushion pad 4A. Because the first extension portion 46b of the reinforcing surface material 46 is extended to reach the sidewall portion on the protruding portion side (upstream side) of the first flow path 42a, the foaming gases and the like that have collected in the recesses of the upper mold 102 pass through the first extension portion 46b and the base portion 46a of the reinforcing surface material 46 and are dispersed and absorbed within the reinforcing surface material 46, as shown in the lower part of FIG. 7 , and / or are discharged to the outside of the mold 100 through the gap C. The arrows in the figure indicate the flow of the foaming gases and the like within the mold 100. In this way, in the cushion pad 4A of the first embodiment, the base portion 46a and the first extension portion 46b of the reinforcing surface material 46 provide an uninterrupted discharge path for the foaming gases and the like. In addition, foaming gas and the like also gathers at the front end portion on the back surface side of the cushion pad 4A, but this foaming gas and the like also passes through the base portion 46a of the reinforcing surface material 46 and is dispersed and absorbed within the reinforcing surface material 46, and / or passes through the gap C and is discharged to the outside of the mold 100.

[0037] As described above, according to the cushion pad 4A of the first embodiment, the air blowing section 40 having the first to ninth flow paths 42a to 42i is formed on the back surface of the cushion pad 4A. Therefore, unlike the conventional structure, it is not necessary to separately mold the pad main body and the loading body. It is possible to integrally mold the cushion pad 4A and the air blowing flow paths 42a to 42i, thereby suppressing an increase in the number of manufacturing steps and costs. Furthermore, the reinforcing surface material 46 has a base portion 46a and a first extension portion 46b extending from the base portion 46a toward the first flow path 42a, and the side wall and bottom wall of the first flow path 42a on the base portion 46a side are covered by the first extension portion 46b, so that foaming gas and the like that gathers at the portions corresponding to the protrusions 45a to 45d within the cavity of the mold 100 during foam molding of the cushion pad 4A passes through the first extension portion 46b and the base portion 46a of the reinforcing surface material 46 and is dispersed and absorbed within the reinforcing surface material 46, and / or passes through the gap C and is discharged to the outside of the mold 100. This makes it possible to reduce the occurrence of molding defects due to gas accumulation during foam molding.

[0038] [Second embodiment] Next, a cushion pad to which a pad structure according to a second embodiment of the present invention is applied will be described. Fig. 8 is a perspective view of the periphery of the air blowing section in the cushion pad of the second embodiment, viewed from the back side. Note that parts that are the same as or correspond to the configuration of the first embodiment shown in Figs. 2 to 7 above will be assigned the same reference numerals and descriptions thereof will be omitted, and the same applies to the other embodiments that follow.

[0039] 8, the configuration of the cushion pad 4B of the second embodiment differs from the configuration of the cushion pad 4A of the first embodiment described above in that a second extension portion 46c is formed in addition to a base portion 46a and a first extension portion 46b in the reinforcing surface material 46. The configuration of the reinforcing surface material 46 other than the second extension portion 46c is the same as in the first embodiment.

[0040] The second extension portion 46c of the reinforcing surface member 46 extends from the first extension portion 46b toward the top surfaces of the first protrusion 45a and the second protrusion 45b. The second extension portion 46c covers the side wall portion of the first flow path 42a located on the side of the protrusions 45a and 45b and the top surfaces of the protrusions 45a and 45b. In other words, the second extension portion 46c is connected to the tip portion of the first extension portion 46b covering the bottom wall portion of the first flow path 42a, and is formed across the side surfaces and top surfaces of the first protrusion 45a and the second protrusion 45b that are adjacent to the first flow path 42a. Therefore, the reinforcing surface material 46 in the second embodiment is configured to cover the back surface of the cushion pad 4B, the inside of the groove of the first flow path 42a (the side wall portion on the base portion 46b side, the bottom wall portion, and the side wall portion on each of the protrusions 45a, 45b side), and the top surfaces of each of the protrusions 45a, 45b, by means of the base portion 46a, the first extension portion 46b, and the second extension portion 46c.

[0041] 9 is a cross-sectional view of the cushion pad 4B of the second embodiment and a mold for foam-molding the same, taken along line AA (see FIG. 3). As shown in FIG. 9, the second extension portion 46c of the reinforcing surface material 46 in the cushion pad 4B covers the side wall portion of the first flow path 42a on the first protrusion 45a side (and the side wall portion on the second protrusion 45b side) and the top surface of the first protrusion 45a (and the top surface of the second protrusion 45b). Therefore, foaming gas and the like that collect in the recesses of the upper mold 102 corresponding to the protrusions 45a and 45b can pass through the second extension portion 46c, the first extension portion 46b, and the base portion 46a of the reinforcing surface material 46 in this order and further through the gap C created by the reinforcing surface material 46 between the lower mold 101 and the upper mold 102. As a result, the foaming gas and the like are dispersed and absorbed within the reinforcing surface material 46 and / or are discharged to the outside of the mold 100 through the gap C.

[0042] Therefore, according to the cushion pad 4B of the second embodiment, with respect to the reinforcing surface material 46 which serves as a discharge path for the foaming gas and the like, the second extension portion 46c which covers the top surfaces of the protruding portions 45a, 45b is disposed continuously from the base portion 46a and the first extension portion 46b, so that a gas discharge path from each of the top surfaces of the protruding portions 45a, 45b, which have shapes which make it easy for gas to accumulate, is established by the reinforcing surface material 46, and the foaming gas and the like can be reliably discharged to the outside of the mold 100. This makes it possible to further reduce the occurrence of molding defects due to gas accumulation during foam molding.

[0043] In the above-mentioned second embodiment, an example was described in which the second extension portion 46c of the reinforcing surface material 46 covers the top surfaces of the first protrusion 45a and the second protrusion 45b adjacent to the first flow path 42a, but the top surfaces of the other protrusions (third protrusion 45c, fourth protrusion 45d) adjacent to the first flow path 42a may also be covered by the second extension portion 46c of the reinforcing surface material 46.

[0044] [Third embodiment] Next, a cushion pad to which a pad structure according to a third embodiment of the present invention is applied will be described. Fig. 10 is a cross-sectional view of the cushion pad of the third embodiment and the cushion frame supporting it taken along line AA (see Fig. 3). Fig. 11 is a plan view of the cushion pad and cushion frame of the third embodiment as viewed from below the vehicle.

[0045] As shown in FIGS. 10 and 11 , in the cushion pad 4C of the third embodiment, the first to fourth protrusions 45a to 45d are located above a cross member 51 extending in the vehicle width direction of the cushion frame 5, and are formed at positions overlapping the cross member 51 on the back surface of the cushion pad 4C in a plan view ( FIG. 11 ) of the cushion frame 5 seen from below the vehicle. The reinforcing surface material 46 of the cushion pad 4C is formed with a third extension 46d in addition to a base portion 46a and a first extension 46b. The cushion pad 4C is further provided with a shielding member 47 (e.g., a PE-coated carpet material) that covers the air blower 40 of the cushion pad 4C. The configuration other than the positional relationship between the protrusions 45a to 45d and the cross member 51, the third extension 46d of the reinforcing surface material 46, and the shielding member 47 is the same as that of the first embodiment. In the third embodiment, the "third extension portion 46d" corresponds to the "second extension portion" of the present invention.

[0046] Specifically, the back surface of the cushion pad 4C is fixed to the cushion frame 5. The cushion frame 5 has a plurality of cross members 51 extending in the vehicle width direction and a pair of side members 52 extending in the vehicle front-rear direction. Each cross member 51 is disposed to bridge between the pair of side members 52. Here, the first to fourth protrusions 45a to 45d of the cushion pad 4C are located above the cross member 51 (see FIG. 11) that is disposed second from the front side of the vehicle among the plurality of cross members 51.

[0047] The third extension portion 46d of the reinforcing surface member 46 extends from the first extension portion 46b toward the top surfaces of the protruding portions 45a to 45d, and covers the side wall portion of the first flow passage 42a located on the side of each of the protruding portions 45a to 45d and a portion of the top surface of each of the protruding portions 45a to 45d. In the third embodiment, the tip portion of the third extension portion 46d extends to a position overlapping with the cross member 51 in a plan view of the cushion frame 5 seen from below the vehicle.

[0048] In the seat cushion portion 2 of the air-conditioned seat 1 to which the cushion pad 4C and the cushion frame 5 configured as described above are applied, when no load from above the vehicle is acting on the cushion pad 4C, the protrusions 45a to 45d are spaced upward from the cross member 51. On the other hand, when a load from above the vehicle acts on the cushion pad 4C, for example, when an occupant sits in the seat, and the cushion pad 4C is deflected downward due to the load, the top surfaces of the protrusions 45a to 45d come into contact with the cross member 51 via the third extension portion 46d of the reinforcing surface member 46 and the shielding member 47. Supporting the protrusions 45a to 45d by the cross member 51 can suppress deformation of the cushion pad 4C, which allows the occupant to feel a sufficient sense of rigidity and prevents the cushion pad 4C from sinking excessively. Furthermore, by suppressing deformation of the cushion pad 4C, the cross-sectional area of ​​each of the flow paths 42a to 42i formed in the blower section 40 can be ensured, and therefore, it is possible to prevent a decrease in the air conditioning performance of the air-conditioned seat 1.

[0049] Furthermore, the third extension portion 46d of the reinforcing surface member 46 continuously covers the side wall portion located on the side of each of the protruding portions 45a to 45d of the first flow path 42a, i.e., the side surface of each of the protruding portions 45a to 45d adjacent to the first flow path 42a, and the top surface of each of the protruding portions 45a to 45d, thereby increasing the strength of each of the protruding portions 45a to 45d and reducing compression of each of the protruding portions 45a to 45d due to the load from the cross member 51. This makes it possible to effectively suppress deformation of the cushion pad 4C.

[0050] [Fourth embodiment] Next, a cushion pad to which a pad structure according to a fourth embodiment of the present invention is applied will be described. Fig. 12 is a perspective view of the periphery of the air blower in the cushion pad of the fourth embodiment, viewed from the back surface side. In Fig. 12, the configuration of the cushion pad 4D of the fourth embodiment differs from the configuration of the cushion pad 4A of the first embodiment described above in that the reinforcing surface material 46 is formed with a fourth extension portion 46e in addition to the base portion 46a and the first extension portion 46b. Note that the configuration of the reinforcing surface material 46 other than the fourth extension portion 46e is the same as in the first embodiment. In the fourth embodiment, the "fourth extension portion 46e" corresponds to the "second extension portion" of the present invention.

[0051] The fourth extension 46e of the reinforcing surface member 46 extends from the first extension 46b toward the top surfaces of the first and second protrusions 45a and 45b. The fourth extension 46e covers the side wall portions of the first flow passage 42a located on the protrusions 45a and 45b side and the top surfaces of the protrusions of the protrusions 45a and 45b that protrude toward the second flow passage 42b. The protrusions of the protrusions 45a and 45b are surrounding portions that contact and are surrounded by the side wall portions of the first to third flow passages 42a to 42c. In other words, the fourth extension 46e connects to the tip portion of the first extension 46b that covers the bottom wall portion of the first flow passage 42a, and is formed across the side surfaces of the protrusions 45a and 45b adjacent to the first flow passage 42a and the top surfaces of the protrusions (surrounding portions). Therefore, the reinforcing surface material 46 in the fourth embodiment is configured to cover the back surface of the cushion pad 4D, the side wall portion on the base portion 46a side of the first flow path 42a, the bottom wall portion and the side wall portion on each protrusion 45a, 45b side, and the top surfaces of the surrounding portions of each protrusion 45a, 45b, by means of the base portion 46a, the first extension portion 46b and the fourth extension portion 46e.

[0052] In the cushion pad 4D of the fourth embodiment described above, the recesses in the upper mold 102 corresponding to the portions surrounded by the protrusions 45a, 45b have few escape routes for gas and the like generated during foam molding, making them the most susceptible to gas accumulation. By providing the fourth extension 46e so that the top surfaces of the portions surrounded by the protrusions 45a, 45b are covered by the reinforcing surface material 46, the foaming gas and the like are efficiently dispersed and absorbed within the reinforcing surface material 46 and / or efficiently discharged to the outside of the mold 100. This makes it possible to accurately reduce molding defects caused by gas accumulation during foam molding.

[0053] [Application example] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and changes are possible based on the technical concept of the present invention. For example, in the above-described embodiments, the pad structure according to the present invention is applied to the cushion pad 4 (4A to 4D) of the seat cushion portion 2 of the air-conditioned seat 1, but a pad structure similar to that of the above-described embodiments can also be applied to the back pad 6 (FIG. 1) of the seat back portion 3.

[0054] An application example to a back pad 6 will be briefly described below with reference to FIG. 13. FIG. 13 is a perspective view of the back pad 6 according to the application example, viewed from the rear surface side. In FIG. 13, a blower 60 is provided on the rear surface of the back pad 6 in the central portion in the vehicle vertical direction. A plurality of groove-shaped flow paths 62a to 62e are formed in the blower 60 and recessed into the front surface side of the back pad 6. Here, a second flow path 62b is formed in the central portion in the vehicle width direction, extending in the vehicle vertical direction, and a first flow path 62a, a third flow path 62c, a fourth flow path 62d, and a fifth flow path 62e are formed extending in the vehicle width direction from both sides of the second flow path 62b. A plurality of openings 61 penetrating the front surface of the back pad 6 are formed in the bottom wall portion of each of the widthwise flow paths 62a, 62c to 62e. A plurality of protrusions 65 protruding toward the rear surface of the back pad 6 are positioned between each of the flow paths 62a to 62e.

[0055] The back pad 6 having the air blowing section 60 having the above-described flow paths 62a to 62i and the plurality of protrusions 65 may be provided with a reinforcing surface material 66 that covers, for example, the portion of the back surface of the back pad 6 that is located outside the air blowing section 60 and the top surfaces of the protrusions 65. This allows the foaming gas and the like that gathers in the recesses of the upper mold corresponding to the protrusions 65 during foam molding to be discharged to the outside of the mold through the reinforcing surface material 66, making it possible to obtain the same effect as in the case of the previously described embodiment. [Explanation of symbols]

[0056] 1...Air-conditioned seats 2...Seat cushion section 3...Seat back 4, 4A~4D...Cushion pad 5...Cushion frame 6...Back pad 7...Back frame 40...Ventilation section 41,61...Opening 42a~42i, 62a~62e...Flow path 45a~45d,65...Protrusion 46,66...Reinforced surface material 46a...base part 46b…1st extension part 46c~46e...2nd~4th extension part 47...Shielding member 100...Mold 101…Lower mold 102...Upper mold

Claims

[Claim 1] an air blowing section in which a plurality of groove-shaped flow paths recessed toward a front surface side are formed on a rear surface of a pad in an air-conditioned seat for a vehicle; openings penetrating from the bottom wall of the plurality of flow paths to the surface of the pad; a reinforcing surface material provided on the back surface of the pad and made of a breathable material; a protrusion formed in the air blowing section of the pad, protruding toward a rear surface of the pad relative to a bottom wall of the plurality of flow paths and positioned between the flow paths; the plurality of flow paths, the air blowing section, the opening, and the protrusion of the pad are integrally formed by foaming, The reinforcing surface material is a base portion that covers a portion of the back surface of the pad that is positioned outside the air blower; a first extension portion that extends from the base portion toward a first flow path that is located between the protruding portion and the base portion among the plurality of flow paths of the blower portion, covers a side wall portion that is located on the base portion side of the first flow path and a bottom wall portion of the first flow path, and has a tip portion that reaches a side wall portion that is located on the protruding portion side of the first flow path, the pad is a cushion pad that constitutes a seat portion of the air-conditioned seat, and a back surface of the cushion pad is fixed to a cushion frame that supports the cushion pad, the protrusion is located above a cross member that extends in a width direction of the cushion frame and has a closed cross-sectional structure, and is provided at a position on a back surface of the cushion pad that overlaps with the cross member in a plan view of the cushion frame seen from below, and the protrusion is surrounded by the plurality of flow paths, the plurality of flow paths include a second flow path extending in a direction intersecting the first flow path, and a third flow path extending in a direction intersecting the second flow path at a position where the protrusion is sandwiched between the second flow path and the first flow path, the protrusion has a surrounding portion that is in contact with and surrounded by each of the side wall portions of the first flow path, the second flow path, and the third flow path, The reinforcing surface material has a second extension portion that extends from the first extension portion toward the top surface of the protrusion and covers the side wall portion located on the protrusion side of the first flow path and the entire top surface of the protrusion including the surrounding portion, and the second extension portion is configured to overlap with the cross member in the planar view.

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