Cushion pad

Abstract

To provide a cushion pad that can suppress the peeling of a bead foam molded body from a soft polyurethane foam molded body, even if the bead foam molded body has a split configuration.SOLUTION: An assembly core pad has a split configuration of a core pad of a block-shaped bead foam molded body, having a first core pad 2 and a second core pad 3. In addition, a recess 4 is formed on one of opposing sides 231, 331 of the first core pad 2 and the second core pad 3, and a protrusion 5 is formed on the other side, and the protrusion 5 fits into the recess 4. A surface layer pad of a soft polyurethane foam molded body forms a seating surface and is laminated to cover a top surface and an outer peripheral side surface of the assembly core pad.SELECTED DRAWING: Figure 1

Description

Technical Field

[0004] , , , , , , , , ,

[0001] The present invention relates to a cushion pad that constitutes a seat portion of a seat sheet.

Background Art

[0002] For example, a cushion pad that constitutes a seat portion of a vehicle seat such as an automobile has been made of a soft polyurethane foam molded body so as to obtain comfortable cushioning properties. Recently, however, there has been a trend towards weight reduction by replacing part of it with a bead foam molded body. However, the bead foam molded body undergoes molding shrinkage during foam molding, resulting in variations in dimensional accuracy. In the manufacture of the cushion pad, it is carried out using a foam molding die having a cavity for the cushion pad that is upside down from the vehicle installation state (see FIG. 10). Even when trying to set the bead foam molded body in the upper mold, there were problems such as the bead foam molded body being difficult to handle and set, or even if it could be set, it would easily fall off immediately. Therefore, several inventions for countermeasures against these problems have been proposed (for example, Patent Documents 1 and 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Disclosure of the Invention

Problems to be Solved by the Invention

[0004] <000002,7>However, Patent Document 1 describes an invention in which the first foamed molded body of a bead foam molded body has a raised portion with a side wall surface that is substantially perpendicular to a part of the back side when the cushion pad is installed on a vehicle, and is limited to cushion pads that do not cause problems even if the raised portion is on the vehicle installation side. Patent Document 2, as described in paragraph 0017, has the advantage that "if the first foamed molded body 3 is separated in the vehicle width direction and divided into multiple parts, the dimensional error due to molding shrinkage in the length between both ends of the first foamed molded body 3 is reduced." However, if Patent Document 2 is divided into two left and right first foamed molded bodies m and n as shown in Figure 13, there is a problem that the number of set steps to attach to the upper mold is doubled due to the separation. Also, because the left first foamed molded body m and the right first foamed molded body n are separated and become smaller, when bending stress is applied when trying to remove the cushion pad during demolding, for example, the right first foamed molded body n may peel off from the back surface fb of the soft polyurethane foam molded body f as shown in Figure 14. The bond between the flexible polyurethane foam molded body f and the first foam molded body of the bead foam molded body is not very strong. Even if the flexible polyurethane foam molded body f covers the first foam molded body of the bead foam molded body and is laminated integrally molded, when it becomes small, as in the first foam molded body n on the right, it will peel off with even a small amount of bending stress. In the figure, the symbol fa indicates the upper surface of the polyurethane foam molded body when installed in the vehicle. The cushion body in Figure 13, which is made by dividing the bead foam molded body into smaller pieces, may cause problems such as the bead foam molded body peeling off from the polyurethane foam molded body f not only during demolding but also during handling and assembly of the cushion body to the vehicle body.

[0005] The present invention aims to solve the above problems and to provide a cushion pad that can suppress the peeling of the bead foam molded body from the soft polyurethane foam molded body, even when the bead foam molded body is in a segmented configuration. [Means for solving the problem]

[0006] To achieve the above objective, the gist of the present invention is a cushion pad comprising: a core pad of a block-shaped bead foam molded body having a first core pad and a second core pad, wherein a recess is formed on one of the opposing sides of the first core pad and the second core pad and a protrusion is formed on the other, and the protrusion fits into the recess; and a surface pad of a soft polyurethane foam molded body that forms a seating surface and is laminated to cover the upper surface and outer peripheral side surface of the assembly core pad. [Effects of the Invention]

[0007] In the cushion pad of the present invention, even when the core pad of the bead foam molded body is divided, a recess is formed on one of the opposing sides of the first core pad and the second core pad and a protrusion is formed on the other, and the protrusion fits into the recess and combines with the assembled core pad. Therefore, the first core pad and the second core pad move as a single unit, so the peeling of the first core pad and the second core pad during demolding and handling is greatly suppressed, and it also becomes easier to handle, exhibiting excellent effects in improving workability and maintaining quality. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view of one embodiment of the cushion pad of the present invention, viewed from the bottom side. [Figure 2] This is a partially cutaway perspective view of the cushion pad, seen from the top. [Figure 3] (a) is a perspective view of the first core pad and the second core pad, and (b) is a perspective view of the assembled core pad. [Figure 4] This is a cross-sectional view taken along line IV-IV in Figure 1. [Figure 5] In the alternative diagram to Figure 3, (a) is a partial perspective view of the first core pad and the second core pad, and (b) is a partial plan view of the assembled core pad with the first core pad and the second core pad fitted together. [Figure 6] Figure 5 is an alternative view showing a different configuration, where (a) is a partial perspective view and (b) is a partial plan view. [Figure 7]Figure 5 is an alternative diagram showing a different configuration, where (a) is a partial perspective view and (b) is a partial cross-sectional view. [Figure 8] Figure 5 is an alternative diagram showing a different configuration, where (a) is a partial perspective view and (b) is a partial cross-sectional view. [Figure 9] This is an explanatory cross-sectional view showing how the assembly core pad is set into the upper mold. [Figure 10] This is an explanatory cross-sectional view showing the injection of polyurethane raw material into the lower mold after Figure 9. [Figure 11] This is a closed explanatory cross-sectional view. [Figure 12] This is a cross-sectional view after the surface pad molding process is complete. [Figure 13] This is a cross-sectional view illustrating the conventional technology. [Figure 14] This is a cross-sectional view illustrating the conventional technology. [Modes for carrying out the invention]

[0009] The cushion pad of the present invention will be described in detail below. Figures 1 to 12 show one embodiment of the cushion pad of the present invention. Figure 1 is a perspective view of the cushion pad seen from the bottom side, Figure 2 is a partially broken perspective view seen from the top side, Figure 3 shows (a) a perspective view of the first core pad and the second core pad and (b) a perspective view of the assembled core pad, Figure 4 is a cross-sectional view of line IV-IV in Figure 1, Figures 5 to 8 are other embodiment diagrams that replace Figures 1 to 4. (a) is a partial perspective view of the first core pad and the second core pad and (b) is a partial plan view or partial cross-sectional view of the assembled core pad with the first core pad and the second core pad fitted together, Figure 9 is a cross-sectional view of setting the assembled core pad in the upper mold, Figure 10 is an explanatory cross-sectional view of injecting polyurethane raw material after Figure 9, Figure 11 is a cross-sectional view with the mold closed, and Figure 12 shows a cross-sectional view after the molding of the surface pad has been completed. For clarity, each diagram has been simplified and the essential parts of the invention are highlighted.

[0010] The cushion pad P here is a seat cushion pad for automobiles and the like that supports the lower body of the seated occupant. This embodiment is applied to the cushion pad P of the rear seat as shown in FIGS. 1 to 4. If a cushion pad cover T is put on the cushion pad P to form a seat cushion, a rear seat sheet with an auxiliary seat portion 6C added at the center in the vehicle width direction can be formed with a seat back obtained by covering a known back pad with a back pad cover. The cushion pad P includes an assembled core pad 1 and a surface layer pad 6.

[0011] The assembled core pad 1 has a first core pad 2 and a second core pad 3 in which the core pad of a block-shaped bead foam molded body is divided, and is a foam molded body in which the first core pad 2 and the second core pad 3 are fitted and assembled. The assembled core pad 1 formed by fitting the first core pad 2 and the second core pad 3 is arranged on the lower surface side of the cushion pad P, and the lower surfaces 2b of the first core pad and 3b of the second core pad are exposed to form the lower layer of the cushion pad P. In the present invention, the "lower surface" refers to the "lower surface" hidden in the drawing in the cushion pad P of FIG. 2 in the mounting attitude on the vehicle, and the "upper surface" refers to the upper surface on which the seated occupant sits. The "front-rear direction" of the present invention refers to the arrow directions of the vehicle rear and the vehicle front in FIG. 2.

[0012] The first core pad 2 and the second core pad 3 constituting the assembled core pad 1 are foam molded bodies such as bead-foamed polypropylene or bead-foamed styrene. For example, if it is a molded body of bead-foamed polypropylene (this embodiment), it becomes a highly foamed layer with an arbitrary magnification inside, and the surface becomes a cured film layer. By using a non-ventilated foam molded body with a surface film, the apparent density after foaming becomes smaller than that of the surface layer pad 6, and the first and second core pads 2 and 3 that are very light for their size can be formed.

[0013] The first core pad 2 and the second core pad 3 have a recess 4 on one of their opposing sides 231 and 331, and a protrusion 5 on the other. When the protrusion 5 fits into the recess 4, it forms a large core pad assembly core pad 1 as shown in Figure 3(b). The first core pad 2 and the second core pad 3 divide the assembly core pad 1 into approximately two equal parts in the vehicle width direction. The lower surface 2b of the first core pad and the lower surface 3b of the second core pad are provided with a groove 12 for accommodating a clip CP. The clip CP becomes the locking part of the locking member K attached to the cushion pad cover T (Figure 4).

[0014] The recess 4 is a groove 4A recessed from the opposing side surface 231 of the first core pad 2 or the opposing side surface 331 of the second core pad 3, and the protrusion 5 is a convex portion 5A that fits into the groove 4A. Here, the protrusion 5 is provided on the first core pad 2 and the recess 4 is provided on the second core pad 3 (Figure 3). The protrusion 5 is formed to protrude, for example, as a rectangular prism-shaped protrusion that forms comb-like teeth on the opposing side surface 231 of the first core pad 2 in Figure 5, and the recess 4 is formed on the opposing side surface 331 of the second core pad 3 that faces the protrusion 5. The assembled core pad 1 is made by horizontally moving the first core pad 2 or the second core pad 3 in Figure 5(a) and fitting the protrusion 5 into the recess 4 as shown in Figure 5(b). In Figure 5(b), the recess 4 and the protrusion 5 engage with each other, restricting and stopping the movement of the first core pad 2 and the second core pad 3 in the vertical direction of the paper (vehicle longitudinal direction), thereby integrating the assembled core pad 1. This embodiment goes a step further, making the recess 4 a dovetail groove 4A that penetrates vertically in a plan view, and the protrusion 5 a convex portion 5A that fits into the dovetail groove 4A (Figures 1 to 4).

[0015] Specifically, as shown in FIG. 3, the first core pad 2 on the right side and the second core pad 3 on the left side, which are divided at approximately the center in the vehicle width direction, are assembled into the assembled core pad 1 by fitting the dovetail-shaped convex portion 5A provided on the opposing side surface 231 of the first core pad 2 into the ant groove-shaped groove 4A provided on the opposing side surface 331 of the second core pad 3. As shown in FIGS. 1 and 3(a), the convex portion 5A shaped like an ant tenon is slid into the ant groove 4A with a narrow groove opening width W40 and an inverted U-shaped cross section from the side (upward in FIG. 3) in the arrow direction, resulting in the assembled core pad 1 shown in FIG. 3(b), so that the first core pad 2 cannot be pulled out in the vertical direction with respect to the opposing side surface 331 of the second core pad 3. The ant groove 4A is formed as a groove 4A that penetrates from the lower surface 3b to the upper surface 3a. Here, the ant groove refers to a groove 4A with an inverted U-shaped cross section, but the ant groove referred to in the present invention is not limited to this, and the groove opening 40 at the mouth is narrow and a part on the groove bottom 41 side is wide. When combined and fitted, similar to the inverted U-shaped groove 4A in FIG. 3(b), it also includes those in which the first core pad 2 cannot be pulled out in the right horizontal direction of the figure from the second core pad 3. For example, a groove 4A that is substantially circular in plan view and has a groove opening 40 and a groove bottom 41 as shown in FIG. 6, and a substantially cylindrical convex portion 5A that fits into the groove 4A correspond to this. The convex portion 5A in FIG. 6 has a larger maximum width t52 of the convex portion 5A than the base end width t50 corresponding to the groove opening 40 side.

[0016] Incidentally, in this embodiment, the recess 4 is made into the groove 4A. Instead of this, the recess 4 can be a recessed hole 4B as shown in FIGS. 7 and 8, and the convex portion 5 can be a protruding portion 5B that fits into the recessed hole 4B. A recessed hole 4B is formed on one of the opposing side surfaces 231 and 331 of the first core pad 2 and the second core pad 3, and a protruding portion 5B such as a columnar shape is formed on the other side. The protruding portion 5B fits into the recessed hole 4B, resulting in an assembled core pad 1 that is an assembled product of the first core pad 2 and the second core pad 3. The protruding tip surface 55 of the protruding portion 5A inserted from the hole opening 45 is close to or abuts on the hole bottom 46, and further, the protruding side surface 56 is close to or abuts on the hole wall 47.

[0017] Furthermore, while there may be only one recess 4 and one protrusion 5, as shown in Figures 1 and 3, multiple recesses 4 (two in this case) can be provided on the opposing side surface 331 of the second core pad 3 in the front-rear direction of the vehicle, and multiple protrusions 5 corresponding to each recess 4 can be provided on the opposing side surface 231 of the first core pad 2 (two in this case). Multiple recesses 4 and protrusions 5 are provided, and each recess 4 and protrusion 5 can be fitted together so as to interlock. The assembled core pad 1 is formed. When multiple recesses 4 and protrusions 5 are provided, the integration of the first core pad 2 and the second core pad 3 becomes stronger, and the combined state of the assembled core pad 1 can be stabilized. When multiple recesses 4 into which the protrusions 5 fit are provided, it is not limited to providing multiple recesses 4 in the front-rear direction of the vehicle on the opposing side surface 331 of the second core pad 3, but may also be provided in the vertical direction of the vehicle on the opposing side surface 231 of the first core pad 2, as shown in Figure 8. Alternatively, multiple recesses 4 may be provided in both the front-rear direction and the vertical direction of the vehicle.

[0018] The surface pad 6 is the surface layer of a foamed molded body that is laminated over the lower assembly core pad 1, and is made of a soft polyurethane foamed molded body. The lower surface of the assembly core pad 1, i.e., the lower surface 2b of the first core pad and the lower surface 3b of the second core pad, is exposed, and the remaining upper surface and outer peripheral side surface of the assembly core pad 1 are covered with the surface pad 6. The assembly core pad 1 is used as an insert, and an upper layer including a seating surface portion 61 is laminated on its upper surface, and a side peripheral layer 62 is laminated on the outer peripheral side surface, so that the surface pad 6, whose back surface 6b abuts against the assembly core pad 1, is foamed and molded. The gaps between the recess 4 and the protrusion 5 where the first core pad 2 and the second core pad 3 that form the assembly core pad 1 fit together, and between the opposing side surfaces 231 and 331, are filled with a soft polyurethane foamed molded body by the foaming of the surface pad 6, as polyurethane raw material g penetrates into these gaps along with the seating surface portion 61 and the side peripheral layer 62. Even though the first and second core pads 2 and 3 are divided to improve dimensional accuracy, the assembly core pad 1, which is fitted together with recesses 4 and protrusions 5, is made as an insert part, and the surface pad 6 is foam-molded, thereby suppressing the peeling of the first core pad 2 and the second core pad 3, resulting in the desired cushion pad P. Reference numeral 6d indicates the side of the surface pad, reference numeral 6A indicates the main part, reference numeral 6B indicates the side part, reference numeral 6E indicates the part that fits with the backrest, and reference numeral 69 indicates the suspension groove.

[0019] The cushion pad P is manufactured, for example, by the following method: Using a foam molding die 7, a soft polyurethane surface pad 6, including the upper surface 6a on the seating surface 611 side that the occupant comes into contact with, is foam-molded to produce a cushion pad P in which the assembly core pad 1 is embedded and integrated during the foam molding process. Prior to manufacturing, the first core pad 2, the second core pad 3, and the foam molding die 7 are prepared.

[0020] The foam molding die 7 is a split type as shown in Figure 10, with the lower die 9 (one split die) and the upper die 8 (the other split die) being able to be opened and closed. When the die is closed as shown in Figure 11, the entire structure is indented into a bowl shape, forming the seating surface 611 for the seated occupant, and the entire structure is almost flat, forming the cushion pad cavity C with the upper die cavity surface 81. The cavity C represents the cross-sectional shape of line IV-IV in Figure 1. Note that the foam molding die 7 in Figures 9 to 12 molds the cushion pad P in Figure 2 in an inverted form.

[0021] First, starting from a state where the first core pad 2 and the second core pad 3 are separated as shown in Figure 3(a), the convex portion 5A of the first core pad 2 is fitted into the groove 4A of the second core pad 3 to form the assembled core pad 1 shown in Figure 3(b). Since the groove 4A is a dovetail groove, the assembled core pad 1 is easy to handle as a single piece. Next, the lower side of the assembled core pad 1 is placed against the upper mold cavity surface 81 of the foam molding die 7 to set the assembled core pad 1 in the upper mold 8 (Figure 9). After setting the assembled core pad 1 in the foam molding die 7, a predetermined amount of polyurethane raw material g for the surface pad 6 is injected onto the lower mold cavity surface 91 using an injection nozzle NL or the like.

[0022] Next, the upper mold 8 is operated to close the mold (Figure 11). The closing of the upper mold 8 and the lower mold 9 creates a cavity C for the cushion pad with the assembly core pad 1 inserted and set. In this embodiment, the mold was closed after injecting the polyurethane raw material g, but it is also possible to inject the polyurethane raw material g after the mold has been closed.

[0023] After the mold is closed, the process proceeds to foam molding of the surface pad 6. The surface pad 6, made of a soft polyurethane foam molded body, has a seating surface portion 61 for the seated occupant on its upper surface 6a, and is foam molded. The mold closed state shown in Figure 11 is maintained for a predetermined time, and the polyurethane raw material g foams and hardens, foam molding the side periphery layer 62 together with the upper layer on which the seating surface portion 61 is located. A portion of the polyurethane raw material g also enters the gaps between the recessed portion 4 and the convex portion 5 and between the opposing side surfaces 231 and 331, and the surface pad 6 is foam molded. The back surface 6b of the surface pad 6 is joined to the upper surfaces 2a, 3a and side surfaces 23, 33 of the assembly core pad 1, i.e., the first core pad 2 and the second core pad 3. After a predetermined time has elapsed, the back surface 6b comes into contact with the upper surface and outer peripheral side surface of the assembly core pad 1, and a surface pad 6 having a side peripheral layer 62 laminated on the outer peripheral side surface of the assembly core pad 1 together with the upper layer including the seating surface portion 61 is foam-molded to obtain the desired cushion pad P as shown in Figure 12. Reference numeral 96 indicates the protruding portion for the suspension groove, and reference numerals 99 and 89 indicate the mold-fitting surface.

[0024] Furthermore, the present invention is not limited to the embodiments shown above, and many modifications are possible within the technical concept of the present invention. In Figures 1 to 6, the groove 4A is formed to penetrate from the lower surface 2b to the upper surface 2a of the first core pad 2, but for example, the groove 4A may be stopped midway from the lower surface 2b to the upper surface 2a, and a convex portion 5A corresponding to the groove 4A may also be formed.

[0025] In this configuration, the cushion pad P is formed by the mechanical connection of the assembly core pad 1 through the fitting of the first core pad 2 and the second core pad 3. Therefore, even if it is made from a bead foam molded body, dimensional errors due to molding shrinkage can be reduced. Consequently, the setting of the first core pad 2 and the second core pad 3 onto the upper mold 8 by locking the clip CP to a locking part (not shown) provided on the upper mold 8 proceeds smoothly. The assembly core pad 1 is formed by creating a recess 4 on one of the opposing sides 231, 331 of the first core pad 2 and the second core pad 3, and a protrusion 5 on the other, with the protrusion 5 fitted into the recess 4. The top surface and outer peripheral side surface of this assembly core pad 1 are covered and laminated with a surface pad 6. This fitting restricts the movement of the first core pad 2 and the second core pad 3 from each other, suppressing peeling from the surface pad 6. Furthermore, since the first core pad 1 and the second core pad 2 move as a single unit, the separation of the first core pad 1 and the second core pad 2 from the surface pad 6 during demolding and handling can be significantly suppressed.

[0026] As explained in Figure 5(b), if the recess 4 is a groove 4A recessed from the opposing side surface 331 of the second core pad 3 (or the opposing side surface 231 of the first core pad 2), and the protrusion 5 is a convex portion 5A that fits into the groove 4A, then even if the first core pad 2 and the second core pad 3 try to move upward or downward on the paper surface due to the fitting, the groove wall 42 and the convex side surface 52 will collide and stop them. Also, even if the first core pad 2, which has been subjected to bending stress during demolding or the like, tries to peel off from the back surface 6b of the surface pad by lifting and tilting its right end side as shown in Figure 14, the surface of the convex top portion 51 of the first core pad 2, which is in contact with or close to the groove bottom 41 of the second core pad 3, will hit the groove bottom 41 and get stuck, thus preventing the first core pad 2 from peeling off.

[0027] Furthermore, in many cases, after the first core pad 2 and the second core pad 3 are assembled into a core pad 1, a loop-shaped wire is fitted into a reinforcement recess (not shown) provided along the outer edge of the assembled core pad 1, and then set into the upper mold 8 shown in Figure 9. However, even though the two divided core pads are connected by a loop-shaped wire, conventionally, the two core pads move independently, which necessitates the use of a setting jig and makes setting the upper mold 8 time-consuming. In contrast, in the present invention, the addition of the loop-shaped wire brings the assembled core pad 1 closer to a single, integrated unit, allowing the setting process into the upper mold 8 to proceed smoothly.

[0028] Furthermore, if the recess 4 becomes the groove 4A of the dovetail groove, and the protrusion 5 is a convex portion 5A that fits into the groove 4A, then even if the first core pad 2 tries to lift and tilt its right end as shown in Figure 14 to detach from the surface pad 6, the surface of the convex top portion 51 that abuts against or is close to the groove bottom 41 will not only hit and get stuck against the surface of the groove bottom 41, but the convex side surface 52 will also hit and get stuck against the groove wall 42 extending from the groove opening 40 to the groove bottom 41, thus reliably preventing the first core pad 2 from detaching. In other words, the groove wall 42 related to the groove 4A of the dovetail groove and the convex side surface 52 of the convex portion 5A are surfaces that have length in the vertical direction of the vehicle as shown in Figure 3, so even if the first core pad 2 tries to lift and tilt its right end as shown in Figure 14, the groove wall 42 and the convex side surface 52 will collide, preventing it from tilting at all. As a result, this cushion pad P cannot be peeled off unless the first core pad 2 and the second core pad 3 peel off together in the upward direction of the paper as shown in Figure 4. When the first core pad 2 and the second core pad 3 are together, even though the bond between the soft polyurethane foam molded body and the bead foam molded body is not particularly strong, the bonding surface with the surface pad 6 doubles, making it impossible to peel off unless subjected to considerable external force. Therefore, by using the assembled core pad 1, dimensional errors can be reduced while more reliably suppressing the peeling of the first core pad 2 and the second core pad 3 of the bead foam molded body from the surface pad 6 of the soft polyurethane foam molded body, resulting in an excellent cushion pad P that contributes to maintaining quality, improving workability, and increasing yield.

[0029] Furthermore, even when the recess 4 is a recessed hole 4B and the convex portion 5 is a projection 5B that fits into the recessed hole 4B, the tip surface 55 of the projection of the first core pad 2, which is in contact with or close to the bottom 46 of the hole of the second core pad 3, not only makes contact with the surface of the bottom 46 but the side surface 56 of the projection also makes contact with the hole wall 47, thus effectively preventing the first core pad 2 and the second core pad 3 from peeling off from the surface pad 6.

[0030] In addition, if multiple recesses 4 and protrusions 5 are provided, and each recess 4 and protrusion 5 is fitted together to interlock and form the assembly core pad 1, the number of fitting points between the recesses 4 and protrusions 5 increases, which increases the number of points where the first core pad 2 and the second core pad 3 restrict each other. As a result, the first core pad 2 and the second core pad 3 are less likely to peel off from the back surface 6b of the surface pad, and the assembly core pad 1 becomes easier to handle, exhibiting excellent effects in improving workability and maintaining quality during the manufacturing of the cushion pad P.

[0031] Furthermore, in this cushion pad P, a portion of the polyurethane raw material g also fills the gaps between the recessed portion 4 and the convex portion 5, and between the opposing side surfaces 231, and the surface pad 6 is foamed and molded. Therefore, even if the first core pad 2 or the second core pad 3 creaks when an occupant sits down, the soft polyurethane foam molded body of the surface pad 6 that fills the gaps does not generate abnormal noise from the two core pads 2 and 3 rubbing against each other, resulting in a high-quality cushion pad P.

[0032] Furthermore, the present invention is not limited to the embodiments shown above, and can be modified in various ways within the scope of the present invention depending on the purpose and application. The shape, size, number, material, etc. of the assembly core pad 1, first core pad 2, second core pad 3, recess 4, protrusion 5, surface pad 6, foam molding die 7, etc. can be appropriately selected according to the application. For example, in the embodiment, the core pad has a first core pad 2 and a second core pad 3 which are divided, and the assembly core pad 1 has a protrusion 5 fitted into a recess 4. However, the assembly core pad 1 may also be divided into a third core pad in addition to the first core pad 2 and the second core pad 3, with a recess 4 formed on one of the opposing side surfaces 231 of the first core pad 2 and the second core pad 3 and a protrusion 5 formed on the other, with the protrusion 5 fitted into the recess 4, and the third core pad similarly fitted into the second core pad 3. [Explanation of Symbols]

[0033] 1. Assembly core pad 2. First core pad (core pad) 231. Opposing side 3. Second core pad (core pad) 4. Recess 4A. Groove (dovetail groove) 5. Protrusion 5A. Convex part 6. Surface pad 611. Seating surface

Claims

1. A core pad comprising a surface pad of a polyurethane foam molded body laminated on its upper surface, which constitutes a cushion pad for a vehicle seat, A block-shaped bead foam molded body is divided and has a first core pad and a second core pad, and a recess is formed on one of the opposing sides of the first core pad and a protrusion on the other, with the protrusion fitting into the recess. Each of the first core pad and the second core pad has a clip housing groove on its lower surface, opposite to the upper surface.

2. The recess is dovetail groove-shaped and the protrusion is a convex portion that fits into the dovetail groove-shaped recess, or the recess is a recessed hole and the protrusion is a projection that fits into the recessed hole. The core pad according to claim 1, wherein in the longitudinal direction of the core pad, the recess and the protrusion are arranged between the housing groove provided in the first core pad and the housing groove provided in the second core pad.

Images