Production method for seat pad reinforcement fabric, production device for seat pad reinforcement fabric, and sheet member

Abstract

Disclosed is a production method for a seat pad reinforcement fabric, said method involving a die having an outer surface that conforms to the shape of the seat pad reinforcement fabric. The die includes a front surface part, a rear surface part, and a plurality of ventilation holes. The front surface part has a first section including at least one among a first recess and a first protrusion, and corresponds to the back part of the seat pad reinforcement fabric. The production method for a seat pad reinforcement fabric includes a step (a), a step (b), a step (c), a step (d), and a step (e). In step (b), an attachment having a second section that conforms to the shape of the first section is positioned on a sheet member that has been fitted over the die, the attachment being positioned so that the first section and the second section correspond. The second section includes a second protrusion corresponding to the first recess and / or a second recess corresponding to the first protrusion, and has rubber elasticity.

Description

Method for manufacturing a seat pad reinforcing cloth, apparatus for manufacturing a seat pad reinforcing cloth, and sheet material

[0001] The present disclosure relates to a method for manufacturing a seat pad reinforcing cloth, a manufacturing device for a seat pad reinforcing cloth, and a sheet material.

[0002] Seat pads are used as cushioning materials in seats used in transportation vehicles. In one example, the seat pad is made of urethane foam or the like. The seat pad is covered with cloth, leather, or the like. The seat pad includes a surface that supports an occupant and a back surface that is attached to a support member. The support member may include, for example, a pipe frame. The support member may include a spring. An occupant protection device or a temperature control device may be attached to the back surface of the seat pad. The back surface of the seat pad is prone to wear because it rubs against the support member due to vibration and occupant movement. Therefore, a seat pad reinforcing cloth may be attached to the back surface of the seat pad to suppress wear of the seat pad.

[0003] Patent Document 1 discloses a method for manufacturing a seat pad reinforcing cloth using a mold having an outer surface that conforms to the seat pad reinforcing cloth. This manufacturing method includes the steps of covering the mold with a sheet material, forming an enclosed space around the sheet material covered on the mold with a cover, heating the sheet material in the enclosed space, and thermoforming the sheet material into a shape that conforms to the outer surface of the mold by evacuating air from the enclosed space.

[0004] Japanese Patent Application Laid-Open No. 2006-281768

[0005] The present disclosure provides a technique for improving the formability of sheet material in the manufacturing process of a seat pad reinforcing fabric.

[0006] According to one aspect of the present disclosure, a method for manufacturing a seat pad reinforcing cloth using a mold having an outer surface conforming to the seat pad reinforcing cloth is disclosed. The mold includes a front portion, a rear portion, and a plurality of ventilation holes. The front portion has a first portion including at least one of a first recess and a first protrusion, and corresponds to the back portion of the seat pad reinforcing cloth. The rear portion faces the front portion in the front-to-rear direction. The plurality of ventilation holes communicate from the outer surface to the interior of the mold. The method for manufacturing the seat pad reinforcing cloth includes steps (a), (b), (c), (d), and (e). Step (a) is a step of covering the mold with a sheet material. Step (b) is a step of placing an attachment having a second portion conforming to the first portion on the sheet material covered over the mold so that the first portion and the second portion correspond to each other. The second portion includes at least one of a second protrusion corresponding to the first recess and a second recess corresponding to the first protrusion, and has rubber elasticity. Step (c) is a step of covering the attachment and sheet material with a cover to form a closed space between the mold and the cover. Step (d) is a step of heating the sheet material. Step (e) is a step of evacuating air from the closed space through a plurality of air vents and pressing the attachment and sheet material against the mold with the cover to process the heated sheet material into a shape that conforms to the outer surface.

[0007] According to another aspect of the present disclosure, an apparatus for manufacturing a seat pad reinforcing cloth is disclosed. The apparatus for manufacturing a seat pad reinforcing cloth includes a mold having an outer surface conforming to the seat pad reinforcing cloth, and an attachment attached to a sheet material placed over the mold. The mold includes a front surface, a rear surface, and multiple ventilation holes. The front surface has a first portion including at least one of a first recess and a first protrusion, and corresponds to the back of the seat pad reinforcing cloth. The rear surface faces the front surface in the front-to-rear direction. The multiple ventilation holes communicate from the outer surface to the interior of the mold. The attachment has a second portion. The second portion includes at least one of a second protrusion corresponding to the first recess and a second recess corresponding to the first protrusion, and has rubber elasticity.

[0008] According to yet another aspect of the present disclosure, there is disclosed a sheet material that is thermoformed while being placed over a mold having an outer surface that conforms to a seat pad reinforcing fabric. The mold has a front portion, a rear portion, and a plurality of ventilation holes. The front portion has a portion including at least one of a recess and a protrusion, and corresponds to the back portion of the seat pad reinforcing fabric. The rear portion faces the front portion in the front-to-rear direction. The plurality of ventilation holes communicate from the outer surface to the interior of the mold. The sheet material has a back portion and a pocket. The back portion is configured to form the back portion of the seat pad reinforcing fabric by thermoforming. The pocket is attached to the back portion so as to form an opening between the back portion and the pocket. The pocket is configured to be hooked onto the mold and faces the rear portion. The pocket has a cutout that exposes the rear portion of the mold.

[0009] The present disclosure improves the formability of sheet material during the manufacturing process of seat pad reinforcing fabric.

[0010] FIG. 1 is a perspective view of a mold according to one embodiment. FIG. 2 is a view showing a sheet material according to this embodiment. FIG. 3 is a perspective view showing an example of a process of covering a mold with a sheet material. FIG. 4 is a perspective view showing an example of a process of placing an attachment on the sheet material. FIG. 5 is a front view showing an attachment according to this embodiment. FIG. 6 is a view showing an example of the inner surface of an attachment according to this embodiment. FIG. 7 is a front view of a mold according to this embodiment. FIG. 8 is a perspective view showing an example of a process of covering an attachment and the sheet material with a cover. FIG. 9 is a perspective view showing an example of a process of heating the sheet material. FIG. 10 is a perspective view showing an example of a process of evacuating air from an enclosed space. FIG. 11 is a perspective view showing an example of a process of removing the cover and the attachment. FIG. 12 is a front view of a seat pad reinforcing cloth according to one embodiment.

[0011] [Outline of the embodiment of the present disclosure] First, an outline of the embodiment of the present disclosure will be described.

[0012] (Clause 1) According to one aspect of the present disclosure, a method for manufacturing a seat pad reinforcing cloth using a mold having an outer surface that conforms to the seat pad reinforcing cloth is disclosed. The mold includes a front portion, a rear portion, and multiple air vents. The front portion has a first portion including at least one of a first recess and a first protrusion, and corresponds to the back of the seat pad reinforcing cloth. The rear portion faces the front portion in the front-to-rear direction. The multiple air vents communicate from the outer surface to the interior of the mold. The method for manufacturing the seat pad reinforcing cloth includes steps (a), (b), (c), (d), and (e). Step (a) is a step of covering the mold with a sheet material. Step (b) is a step of placing an attachment having a second portion that conforms to the first portion on the sheet material covered over the mold so that the first portion and the second portion correspond to each other. The second portion includes at least one of a second protrusion corresponding to the first recess and a second recess corresponding to the first protrusion, and has rubber elasticity. Step (c) is a step of covering the attachment and sheet material with a cover to form a closed space between the mold and the cover. Step (d) is a step of heating the sheet material. Step (e) is a step of evacuating air from the closed space through a plurality of air vents and pressing the attachment and sheet material against the mold with the cover to process the heated sheet material into a shape that conforms to the outer surface.

[0013] According to the above-described method for manufacturing a seat pad reinforcing cloth, in step (b), the sheet material is sandwiched between the mold and the attachment. Since steps (c), (d), and (e) are performed after step (b), the sheet material is thermoformed while sandwiched between the mold and the attachment. The portion of the sheet material that covers the first portion of the mold is thermoformed while sandwiched between the first portion of the mold and the second portion of the attachment. The first portion includes at least one of a first recess and a first protrusion. The second portion includes at least one of a second protrusion corresponding to the first recess and a second protrusion corresponding to the first protrusion, and has rubber elasticity, so that the sandwiched portion of the sheet material is pressed to conform to the shape of the first portion. As a result, the sheet material is molded into a shape that conforms to at least one of the first recess and the first protrusion of the first portion. Therefore, the above-described method for manufacturing a seat pad reinforcing cloth improves the formability of the sheet material during the manufacturing process of the seat pad reinforcing cloth.

[0014] (Clause 2) In the manufacturing method of the seat pad reinforcing cloth described in Clause 1, at least one of the first convex portion and the second convex portion may include a plurality of ribs. The plurality of ribs may extend with the first direction as the longitudinal direction. The first direction is perpendicular to the front-to-rear direction. The plurality of ribs are adjacent to each other in the second direction. The second direction is perpendicular to the front-to-rear direction and the first direction. At least one of the first recess and the second recess may include a plurality of grooves. The plurality of grooves may extend with the first direction as the longitudinal direction so as to be recessed along the plurality of ribs. The plurality of grooves are adjacent to each other in the second direction. According to this manufacturing method of the seat pad reinforcing cloth, the sheet material is molded into a shape that follows the area between at least one of the areas between adjacent ribs and the areas between adjacent grooves.

[0015] (Clause 3) In the manufacturing method of the seat pad reinforcing cloth described in Clause 2, the plurality of ribs may be a plurality of first ribs. The plurality of grooves may be a plurality of first grooves. At least one of the first convex portion and the second convex portion may include a plurality of second ribs. The plurality of second ribs extend with the second direction as a longitudinal direction. The plurality of second ribs are adjacent to each other in the first direction. At least one of the first recessed portion and the second recessed portion may include a plurality of second grooves. The plurality of second grooves extend with the second direction as a longitudinal direction so as to be recessed along the plurality of second ribs. The plurality of second grooves are adjacent to each other in the first direction. According to this manufacturing method of the seat pad reinforcing cloth, the sheet material is formed into a shape that follows at least one of the regions between adjacent first ribs and the regions between adjacent first grooves, and is formed into a shape that follows at least one of the regions between adjacent second ribs and the regions between adjacent second grooves.

[0016] (Clause 4) In the method for manufacturing a seat pad reinforcing cloth according to Clause 2 or 3, the minimum width in the second direction of one of the plurality of ribs may be smaller than the maximum width in the second direction between adjacent ribs among the plurality of ribs. According to this method for manufacturing a seat pad reinforcing cloth, the sheet material is formed into a shape that conforms to an area between adjacent ribs that is wider than the minimum width of one rib.

[0017] (Clause 5) In the method for manufacturing a seat pad reinforcing cloth according to any one of clauses 2 to 4, the mold may include at least one first ferromagnetic body. The at least one ferromagnetic body is embedded in at least one of the regions between adjacent ribs of the first convex portion and between adjacent grooves of the first concave portion. The attachment may include at least one second ferromagnetic body. The at least one second ferromagnetic body is embedded in at least one of the regions between adjacent ribs of the second convex portion and between adjacent grooves of the second concave portion. The at least one first ferromagnetic body and the at least one second ferromagnetic body may be configured to attract each other by magnetic force in step (b). According to this method for manufacturing a seat pad reinforcing cloth, the regions between adjacent ribs of the first convex portion and the regions between adjacent grooves of the second concave portion attract each other, or the regions between adjacent grooves of the first concave portion and the regions between adjacent ribs of the second convex portion attract each other. As a result, the sheet material is molded into a shape that conforms to the first convex portion or the first concave portion.

[0018] (Clause 6) In the method for manufacturing a seat pad reinforcing cloth according to any one of clauses 1 to 5, the sheet material may include a back surface and a pocket. The back surface is configured to be formed as the back portion of the seat pad reinforcing cloth by thermoforming. The pocket is formed on the back surface so as to define a space between the back surface and the pocket. The pocket is configured to be hooked onto a mold and is configured to face the rear surface portion. In step (a), the pocket may be hooked onto the mold. According to this method for manufacturing a seat pad reinforcing cloth, the sheet material is placed over the mold by hooking the pocket onto the mold in step (a). By hooking the pocket onto the mold, the positional relationship between the mold and the sheet material is more stable than when a sheet material without a pocket is placed over the mold. As a result, the sheet material is more likely to conform to the outer surface of the mold, and this method for manufacturing a seat pad reinforcing cloth improves the formability of the sheet material.

[0019] (Clause 7) The manufacturing method of a seat pad reinforcing cloth according to any one of clauses 1 to 6 may further include step (b1). The mold may further include side portions corresponding to the side portions of the seat pad reinforcing cloth. The side portions may be adjacent to the front portion in the left-right direction and may protrude further forward than the front portion in the front-to-rear direction. The left-to-right direction is perpendicular to the front-to-rear direction. The attachment may be a first attachment. In step (b1), a second attachment including a corner portion may be placed on the sheet material hung on the mold so that the interior corner corresponds to the corner. The interior angle is defined by the side portion and the front portion. The corner protrudes along the interior angle. According to this manufacturing method of a seat pad reinforcing cloth, the sheet material is formed into a shape that follows the interior angle defined by the side portion and the front portion.

[0020] (Clause 8) The method for manufacturing a seat pad reinforcing cloth according to any one of clauses 1 to 7 may further include steps (f) and (g). The mold may further include side portions corresponding to the side portions of the seat pad reinforcing cloth. The side portions may be adjacent to the front portion in the left-right direction and may protrude forward of the front portion in the front-rear direction. The left-right direction is orthogonal to the front-rear direction. In step (f), the cover and attachment may be removed. In step (g), a plurality of slits may be formed in the portion of the sheet material covering the mold corresponding to the side portions, with the vertical direction as the longitudinal direction and aligned along the vertical direction. The vertical direction is orthogonal to the front-rear direction and the left-right direction. According to this method for manufacturing a seat pad reinforcing cloth, a plurality of slits aligned along the vertical direction are formed in the side portions of the seat pad reinforcing cloth. A single long slit corresponding to the entirety of the plurality of slits is easily opened when the seat pad reinforcing cloth and the seat pad are joined. The multiple slits aligned along the vertical direction on the side of the seat pad reinforcing cloth are each shorter in length than a single long slit, so they are less likely to open when joining the seat pad reinforcing cloth and the seat pad. This method of manufacturing the seat pad reinforcing cloth makes it easy to join the seat pad reinforcing cloth and the seat pad.

[0021] (Clause 9) The method for manufacturing a seat pad reinforcing cloth according to any one of clauses 1 to 8 may further include steps (f) and (g1). In step (f), the cover and the attachment may be removed. In step (g1), an opening may be formed in at least one of the bottom surface of the recess corresponding to the first recess and the top surface of the protrusion corresponding to the first protrusion, in a portion of the sheet material covering the mold that corresponds to the first portion of the front surface. In this method for manufacturing a seat pad reinforcing cloth, the opening is formed with the sheet material facing the mold, so that the opening can be easily formed in at least one of the top surface of the protrusion and the bottom surface of the recess.

[0022] (Clause 10) According to another aspect of the present disclosure, a manufacturing apparatus for a seat pad reinforcing cloth is disclosed. The manufacturing apparatus for a seat pad reinforcing cloth includes a mold having an outer surface conforming to the seat pad reinforcing cloth, and an attachment attached to a sheet material placed over the mold. The mold includes a front surface, a rear surface, and multiple ventilation holes. The front surface has a first portion including at least one of a first recess and a first protrusion, and corresponds to the back of the seat pad reinforcing cloth. The rear surface faces the front surface in the front-to-rear direction. The multiple ventilation holes communicate from the outer surface to the interior of the mold. The attachment includes at least one of a second protrusion corresponding to the first recess and a second recess corresponding to the first protrusion, and includes a second portion having rubber elasticity. Similar to Clause 1, this manufacturing apparatus for a seat pad reinforcing cloth improves the formability of the sheet material during the manufacturing process of the seat pad reinforcing cloth.

[0023] (Clause 11) In the manufacturing device for seat pad reinforcing cloth described in Clause 10, at least one of the first convex portion and the second convex portion may include a plurality of ribs. The plurality of ribs may extend with the first direction as the longitudinal direction. The first direction is perpendicular to the front-rear direction. The plurality of ribs are adjacent to each other in the second direction. The second direction is perpendicular to the front-rear direction and the first direction. At least one of the first recess and the second recess may include a plurality of grooves. The plurality of grooves may extend with the first direction as the longitudinal direction so as to be recessed along the plurality of ribs. The plurality of grooves are adjacent to each other in the second direction. According to this manufacturing device for seat pad reinforcing cloth, the sheet material is formed into a shape that follows at least one of the areas between adjacent ribs and the areas between adjacent grooves.

[0024] (Clause 12) In the manufacturing device for a seat pad reinforcing cloth according to Clause 11, the plurality of ribs may be a plurality of first ribs. The plurality of grooves may be a plurality of first grooves. At least one of the first convex portion and the second convex portion may include a plurality of second ribs. The plurality of second ribs extend with the second direction as a longitudinal direction. The plurality of second ribs are adjacent to each other in the first direction. At least one of the first recessed portion and the second recessed portion may include a plurality of second grooves. The plurality of second grooves extend with the second direction as a longitudinal direction so as to be recessed along the plurality of second ribs. The plurality of second grooves are adjacent to each other in the first direction. According to this manufacturing device for a seat pad reinforcing cloth, the sheet material is formed into a shape that follows at least one of the regions between adjacent first ribs and the regions between adjacent first grooves, and is formed into a shape that follows at least one of the regions between adjacent second ribs and the regions between adjacent second grooves.

[0025] (Clause 13) In the manufacturing device for a seat-pad reinforcing cloth according to Clause 11 or 12, the minimum width in the second direction of one of the plurality of ribs may be smaller than the maximum width in the second direction between adjacent ribs among the plurality of ribs. According to this manufacturing device for a seat-pad reinforcing cloth, the sheet material is formed into a shape that conforms to an area between adjacent ribs that is wider than the minimum width of one rib.

[0026] (Clause 14) In the manufacturing device for a seat pad reinforcing cloth according to any one of clauses 11 to 13, the mold may include at least one first ferromagnetic body. The at least one ferromagnetic body is embedded in at least one of the regions between adjacent ribs of the first convex portion and between adjacent grooves of the first concave portion. The attachment may include at least one second ferromagnetic body. The at least one second ferromagnetic body is embedded in at least one of the regions between adjacent ribs of the second convex portion and between adjacent grooves of the second concave portion. The at least one first ferromagnetic body and the at least one second ferromagnetic body may be configured to attract each other by magnetic force. According to this manufacturing device for a seat pad reinforcing cloth, as in clause 5, the sheet material is formed into a shape that conforms to the first convex portion or the first concave portion.

[0027] (Clause 15) The manufacturing device for a seat pad reinforcing cloth according to any one of clauses 10 to 14 may include a second attachment. The attachment may be the first attachment. The mold may further include side portions corresponding to the side portions of the seat pad reinforcing cloth. The side portions are adjacent to the front portion in the left-right direction perpendicular to the front-to-rear direction and protrude forward of the front portion in the front-to-rear direction. The second attachment includes a corner portion that protrudes along an interior angle formed by the side portion and the front portion. According to this manufacturing device for a seat pad reinforcing cloth, the sheet material is formed into a shape that follows the interior angle formed by the side portion and the front portion.

[0028] (Clause 16) The manufacturing apparatus for a seat pad reinforcing cloth according to any one of clauses 10 to 15 may further include a processing machine. The mold may further include side portions corresponding to the side portions of the seat pad reinforcing cloth. The side portions are adjacent to the front portion in the left-right direction and protrude forward of the front portion in the front-to-rear direction. The left-to-right direction is perpendicular to the front-to-rear direction. The processing machine may be configured to form a plurality of slits aligned along the up-to-down direction in the portion of the sheet material placed over the mold corresponding to the side portions, with the up-to-down direction being the longitudinal direction. The up-to-down direction is perpendicular to the front-to-rear and left-to-right directions. This manufacturing apparatus for a seat pad reinforcing cloth, like that of clause 8, facilitates joining of the seat pad reinforcing cloth and the seat pad.

[0029] (Clause 17) The manufacturing apparatus for a seat pad reinforcing cloth according to any one of clauses 10 to 16 may further include a processing machine. The processing machine is configured to form an opening in at least one of the bottom surface of a recess corresponding to the first recess and the top surface of a protrusion corresponding to the first protrusion, in a portion of the sheet material placed over the mold that corresponds to the first portion of the front surface. In this manufacturing apparatus for a seat pad reinforcing cloth, as in clause 9, an opening can be easily formed in at least one of the top surface of the protrusion and the bottom surface of the recess.

[0030] (Clause 18) According to yet another aspect of the present disclosure, there is disclosed a sheet material that is thermoformed while being placed over a mold having an outer surface that conforms to a seat pad reinforcing fabric. The mold includes a front portion, a rear portion, and a plurality of ventilation holes. The front portion has a portion including at least one of a recess and a protrusion, and corresponds to the back portion of the seat pad reinforcing fabric. The rear portion faces the front portion in the front-to-rear direction. The plurality of ventilation holes communicate from the outer surface to the interior of the mold. The sheet material includes a back portion and a pocket. The back portion is configured to be formed as the back portion of the seat pad reinforcing fabric by thermoforming. The pocket is formed on the back portion to define a space between the back portion and the pocket. The pocket is configured to be hooked onto the mold and faces the rear portion. The pocket has a cutout formed therein that is configured to expose the rear portion of the mold.

[0031] According to the above-described sheet material, the sheet material is placed over the mold by hooking the pocket onto the mold. By hooking the pocket onto the mold, the positional relationship between the mold and the sheet material is more stable than when a sheet material without a pocket is placed over the mold. Furthermore, the pocket has a cutout that exposes the rear surface of the mold. The rear surface of the sheet material is thermoformed to conform to a portion of the front surface of the mold that includes at least one of a recess and a protrusion. The amount of deformation of the rear surface of the sheet material at the front surface of the mold is greater than the amount of deformation of the rear surface of the sheet material at the front surface of the mold that does not include the recess or protrusion. Therefore, tension corresponding to the amount of deformation of the rear surface is applied to the pocket attached to the rear surface. Because the pocket cutout opens in response to the tension applied to the pocket, the pocket does not easily hinder the deformation of the rear surface of the sheet material. As a result, this sheet material improves the formability of the sheet material during the manufacturing process of the seat pad reinforcing fabric.

[0032] (Clause 19) In the sheet material according to clause 18, the notch may be continuous with the opening edge that defines the opening of the pocket. In this sheet material, the notch opens due to tension applied to the opening edge of the pocket, making it even less likely to inhibit deformation of the back surface of the sheet material.

[0033] [Examples of embodiments of the present disclosure] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. In the description of the drawings, the same elements are given the same reference numerals, and duplicate descriptions will be omitted as appropriate.

[0034] FIG. 1 is a perspective view of a mold according to this embodiment. FIG. 2 is a diagram showing a sheet material according to this embodiment. Below, with reference to FIGS. 1 to 3, a manufacturing apparatus 100 for a seat pad reinforcing cloth (hereinafter referred to as "manufacturing apparatus 100"), a manufacturing method MT for a seat pad reinforcing cloth (hereinafter referred to as "manufacturing method MT"), and a sheet material 200 will be described. The manufacturing apparatus 100 is a manufacturing apparatus for making the sheet material 200 into a seat pad reinforcing cloth S. The manufacturing method MT is a manufacturing method for making the sheet material 200 into a seat pad reinforcing cloth S. The manufacturing method MT may be performed using the manufacturing apparatus 100.

[0035] The manufacturing apparatus 100 includes a mold 1 and an attachment 2. The mold 1 has an outer surface 1s that conforms to the seat pad reinforcing cloth S. The attachment 2 will be described later. The manufacturing method MT is a method for manufacturing the seat pad reinforcing cloth S using the mold 1 that has an outer surface 1s that conforms to the seat pad reinforcing cloth S. The manufacturing apparatus 100 may further include a base 101, an air supply and exhaust unit 102, and a heating unit 103.

[0036] In the example shown in FIG. 1 , the mold 1 is fixed to a base 101. The air intake and exhaust unit 102 and the heating unit 103 are connected to the base 101. In one example, the air intake and exhaust unit 102 includes a blower configured to supply and exhaust air. In one example, the heating unit 103 includes a heater. The heating unit 103 is configured to heat the air supplied from the air intake and exhaust unit 102. A space may be formed inside the mold 1. A space may be formed inside the base 101. The interior of the mold 1 is in communication with the interior of the base 101. The air intake and exhaust unit 102 is connected to the mold 1 via the base 101. In one example, the mold 1 is made of aluminum. The mold 1 may also be made of resin.

[0037] The mold 1 includes a front portion 1a, a rear portion 1b, and a plurality of ventilation holes 1h. The front portion 1a corresponds to the back portion Sa of the seat pad reinforcing cloth S. The back portion Sa of the seat pad reinforcing cloth S is formed by the front portion 1a. The front portion 1a has a first portion 10 including at least one of a first recess and a first protrusion. Details of the first portion 10 will be described later. The rear portion 1b faces the front portion 1a in the front-to-rear direction D1. The wraparound portion of the seat pad reinforcing cloth S is formed by the rear portion 1b. The plurality of ventilation holes 1h communicate from the outer surface 1s to the interior of the mold. In one example, the plurality of ventilation holes 1h includes 100 or more ventilation holes. For example, a plurality of ventilation holes 1h are formed on each of the outer surface 1s of the front portion 1a and the outer surface 1s of the rear portion 1b.

[0038] The mold 1 may include side portions 1c. In the example shown in FIG. 1, the mold includes a pair of side portions 1c. The side portions 1c correspond to the side portions Sc of the seat pad reinforcing cloth S. The side portions Sc of the seat pad reinforcing cloth S are formed by the side portions 1c. The side portions 1c are adjacent to the front portion 1a in the left-right direction D2. The left-right direction D2 is perpendicular to the front-rear direction D1. The side portions 1c protrude further forward than the front portion 1a in the front-rear direction D1.

[0039] The mold 1 may include a protrusion 1d. The protrusion 1d protrudes upward from the upper end of the mold 1 in the up-down direction D3. The up-down direction D3 is perpendicular to the front-rear direction D1 and the left-right direction D2. The protrusion 1d may be rod-shaped. In the example shown in FIG. 1 , the mold 1 includes a pair of protrusions 1d. The protrusions 1d correspond to the through holes of the seat pad reinforcing cloth S. The inner edge defining the through holes of the seat pad reinforcing cloth S is formed by the side surface portion 1c.

[0040] The sheet material 200 shown in FIG. 2 is thermoformed while being placed over a mold 1 having an outer surface 1s that conforms to the seat pad reinforcing fabric S. The sheet material 200 is formed from a material that is breathable to air. In one example, the sheet material 200 may be formed from a nonwoven fabric. The nonwoven fabric may include high-melting point fibers and low-melting point fibers. The sheet material 200 may also include a thermoplastic resin. By melting the low-melting point fibers or the thermoplastic resin during thermoforming, the sheet material 200 is thermoformed to conform to the outer surface 1s of the mold 1. As a result, the sheet material 200 is thermoformed into the shape of the seat pad reinforcing fabric S.

[0041] The sheet material 200 includes a back surface 21 and a pocket 22. The back surface 21 is configured to be formed as a back portion Sa of the seat pad reinforcing cloth S by thermoforming. The pocket 22 is formed on the back surface 21 so as to define a space between the back surface 21 and the pocket 22. The pocket 22 includes an opening edge 23 that opens downward. The pocket 22 may be formed by joining pieces of cloth. In the example shown in FIG. 2 , the back surface 21 and the pocket 22 are formed by folding a piece of cloth and joining the edges of parts of the piece of cloth to each other. The joining of the cloth is performed by sewing, gluing, or welding.

[0042] As shown in Figure 2, the sheet material 200 includes a plurality of joints 22a extending from the center of the pocket 22 toward the outer edge when viewed in the front-to-rear direction D1. The joints 22a are linear portions formed by joining a pair of edges. The edge of the back surface 21 in the left-to-right direction D2 and the edge of the pocket 22 in the left-to-right direction D2 are connected by folds 25. There are a pair of folds 25. The folds 25 include the edge of the opening edge 23 of the pocket 22 in the left-to-right direction D2.

[0043] The upper end of the back surface 21 in the vertical direction D3 and the upper end of the pocket 22 in the vertical direction D3 are connected by a folded portion 26. The folded portion 26 includes the bottom of the pocket 22. A through hole 26h may be formed in the folded portion 26. The through hole 26h corresponds to the protrusion 1d. In the example shown in FIG. 2, a pair of through holes 26h are formed in the folded portion 26. The folded portions 25, 26 are portions where the fabric is folded. Note that the end of the pocket 22 may be joined to the back surface 21 by a joining portion instead of the folded portions 25, 26.

[0044] As shown in Figures 2 and 3, the pocket 22 is configured to be hooked onto the mold 1. The back surface 21 is configured to face the front surface 1a of the mold 1. The pocket 22 is configured to face the rear surface 1b of the mold 1. The pocket 22 is hooked onto the mold 1 by accommodating a part of the mold 1 in the space between the back surface 21 and the pocket 22. The pocket 22 has a cutout 27 formed therein that is configured to expose the rear surface 1b of the mold 1. The cutout 27 may be a slit. It is sufficient that the cutout 27 is configured to expose the rear surface 1b after the sheet material 200 has been thermoformed. The cutout 27 extends in a direction different from the direction in which the lower end of the pocket 22 extends.

[0045] The maximum width of the notch 27 in the up-down direction D3 may be greater than the maximum width of the notch 27 in the left-right direction D2. The notch 27 may be continuous with the opening edge 23 that defines the opening of the pocket 22. In this case, the edge 28 that defines the notch 27 and the opening edge 23 that defines the opening may be integrally configured. The opening edge 23 that defines the opening includes the lower edge of the pocket 22. The edge 28 that defines the notch 27 includes the ends of the pocket 22 excluding the lower edge.

[0046] Hereinafter, each step of the manufacturing method MT and the detailed configuration of the manufacturing apparatus 100 will be described with reference to FIGS. 3 to 12. The manufacturing method MT includes steps STa, STb, STc, STd, and STe. The manufacturing method MT starts with step STa. As shown in FIG. 3, step STa is a step of covering the mold 1 with a sheet material 200. The sheet material 200 may be covered on the mold 1 by hooking the pocket 22 onto the mold 1. The protrusion 1d of the mold 1 may be inserted into the through-hole 26h of the sheet material 200.

[0047] Next, step STb is performed. FIG. 4 is a perspective view showing an example of a step of placing an attachment on a sheet material. As shown in FIG. 4, step STb is a step of placing an attachment 2 on a sheet material 200 that has been placed on a mold 1. Details of the mold 1, the attachment 2, and step STb will be described below with reference to FIGS. 4 to 7. FIG. 4 is a perspective view showing an example of a step of placing an attachment on a sheet material. FIG. 5 is a front view showing an attachment according to this embodiment. FIG. 6 is a view showing an example of the inner surface of an attachment according to this embodiment. FIG. 7 is a front view of a mold according to this embodiment.

[0048] The front surface 1a of the mold 1 has a first portion 10 including at least one of a first recess and a first protrusion. In the example shown in Figure 7, the first portion 10 includes a protrusion 11 and a plurality of protrusions 12 as the first protrusion. The first portion 10 includes a plurality of recesses 13 as the first recess. The attachment 2 includes a second portion 30. As shown in Figure 6, the second portion 30 includes at least one of a second protrusion corresponding to the first recess and a second recess corresponding to the first protrusion. In the example shown in Figure 6, the second portion 30 includes a recess 31 and a plurality of grooves 32 as the second recess. The second portion 30 includes a plurality of protrusions 33 as the second protrusion.

[0049] The recess 31 corresponds to the protrusion 11. The recess 31 is configured to be able to accommodate the protrusion 11. The plurality of grooves 32 corresponds to the plurality of protrusions 12. The plurality of grooves 32 is configured to be able to accommodate the plurality of protrusions 12, respectively. The plurality of recesses 13 corresponds to the plurality of protrusions 33. The plurality of grooves 32 is configured to be able to accommodate the plurality of protrusions 12, respectively.

[0050] The second portion 30 has rubber elasticity. Rubber elasticity is also referred to as viscoelasticity or entropy elasticity. The second portion 30 is formed, for example, from an elastomer material. Elastomer materials include thermoplastic elastomers and thermosetting elastomers. In one example, the second portion 30 is formed from silicone. The entire attachment 2, including the second portion 30, may be formed from an elastomer material.

[0051] Referring now to FIG. 7 , at least one of the first convex portion and the second convex portion may include multiple ribs. In the example shown in FIG. 7 , the convex portion 11 includes two ribs 11a as the multiple ribs. The multiple ribs 11a extend with the vertical direction D3 as the longitudinal direction. The vertical direction D3 is an example of a first direction. The multiple ribs 11a are adjacent to each other in the horizontal direction D2. The horizontal direction D2 is an example of a second direction. The multiple ribs 11a extend so as to protrude downward in the vertical direction D3. The multiple ribs 11a include the lower ends of the convex portion 11. The length of the multiple ribs 11a in the vertical direction D3 is at least half the length of the convex portion 11 in the vertical direction D3. The minimum width of one of the multiple ribs 11a in the horizontal direction D2 is smaller than the maximum width in the horizontal direction D2 between adjacent ribs 11a.

[0052] The multiple ribs 11a may be first ribs. At least one of the first convex portion and the second convex portion may include multiple second ribs. In the example shown in FIG. 7 , the convex portion 11 includes ribs 11b, rib 11c, rib 11d, and rib 11e as multiple second ribs. The ribs 11b, 11c, 11d, and 11e extend with the left-right direction D2 as their longitudinal direction. The ribs 11b and 11c are adjacent to each other in the up-down direction D3. The rib 11b is located higher than the rib 11c in the up-down direction D3. The ribs 11d and 11e are adjacent to each other in the up-down direction D3. The rib 11d is located higher than the rib 11e in the up-down direction D3. The ribs 11b and 11d include the upper ends of the convex portion 11.

[0053] The ribs 11b and 11c extend so as to protrude leftward in the left-right direction D2. The rib 11c protrudes further left than the rib 11b. The ribs 11d and 11e extend so as to protrude rightward in the left-right direction D2. The rib 11e protrudes further right than the rib 11c. The minimum width of one of the ribs 11b and 11c in the up-down direction D3 is smaller than the maximum width between the adjacent ribs 11b and 11c in the up-down direction. The minimum width of one of the ribs 11d and 11e in the up-down direction D3 is smaller than the maximum width between the adjacent ribs 11d and 11e in the up-down direction.

[0054] The recesses 13 extend in the up-down direction D3 as their longitudinal direction. The recesses 13 include recesses 13a, 13b, and 13c that are adjacent to each other in the left-right direction D2. Recess 13a is located above rib 11b. Recess 13c is located above rib 11d. Recess 13b is located between recesses 13a and 13c.

[0055] The multiple protrusions 12 include protrusion 12a and protrusion 12b. Protrusions 12a and 12b extend to surround ribs 11b and 11d. Protrusion 12a includes a lower left end adjacent to rib 11b in the left-right direction D2, a lower right end adjacent to rib 11d in the left-right direction D2, and an extending portion adjacent to ribs 11b and 11d in the up-down direction D3 and connecting the lower left end and the lower right end. Protrusion 12b is located outward from protrusion 12a. Protrusion 12b extends along protrusion 12a.

[0056] The front surface portion 1a may include multiple protrusions 14. The multiple protrusions 14 include protrusions 14a and 14b. The protrusion 14a includes an upper left end adjacent to the left-most rib 11a in the left-right direction D2, an upper right end adjacent to the right-most rib 11a in the left-right direction D2, and an extending portion adjacent to the multiple ribs 11a in the up-down direction D3 and connecting the upper left end and the upper right end. The protrusion 14b is located outward from the protrusion 14a. The protrusion 14b extends along the protrusion 14a.

[0057] Referring now to FIG. 6 , at least one of the first recess and the second recess may include multiple grooves. In the example shown in FIG. 6 , the recess 31 includes two grooves 31a as the multiple grooves. The multiple grooves 31a extend in the vertical direction D3 as the longitudinal direction so as to be recessed along the multiple ribs 11a. The multiple grooves 31a extend so as to protrude downward in the vertical direction D3. The multiple grooves 31a include the lower end of the recess 31. The multiple grooves 31a are adjacent to each other in the horizontal direction D2. The minimum width of the grooves 31a in the horizontal direction D2 is smaller than the maximum width in the horizontal direction D2 between the adjacent multiple grooves 31a. The multiple grooves 31a correspond to the multiple ribs 11a. The multiple grooves 31a are configured to accommodate the multiple ribs 11a.

[0058] The plurality of grooves 31a may be first grooves. At least one of the first recess and the second recess may include a plurality of second grooves. In the example shown in FIG. 6 , the recess 31 includes grooves 31b, 31c, 31d, and 31e as the plurality of second grooves. The grooves 31b, 31c, 31d, and 31e extend along the left-right direction D2 as their longitudinal direction so as to be recessed along the ribs 11b, 11c, 11d, and 11e, respectively. The grooves 31b and 31c are adjacent to each other in the up-down direction D3. The groove 31b is located above the groove 31c in the up-down direction D3. The grooves 31d and 31e are adjacent to each other in the up-down direction D3. The groove 31d is located above the groove 31e in the up-down direction D3. The grooves 31b and 31d include the upper ends of the recess 31.

[0059] Grooves 31b and 31c extend so as to protrude leftward in the left-right direction D2. Groove 31c protrudes more leftward than groove 31b. Grooves 31d and 31e extend so as to protrude rightward in the left-right direction D2. Groove 31e protrudes more rightward than groove 31c. The minimum width of one of grooves 31b and 31c in the up-down direction D3 is smaller than the maximum width between adjacent grooves 31b and 31c in the up-down direction. The minimum width of one of grooves 31d and 31e in the up-down direction D3 is smaller than the maximum width between adjacent grooves 31d and 31e in the up-down direction.

[0060] The multiple protrusions 33 extend with the vertical direction D3 as their longitudinal direction. The multiple protrusions 33 include protrusions 33a, 33b, and 33c that are adjacent to each other in the horizontal direction D2. Protrusion 33a is located above groove 31b. Protrusion 33c is located above groove 31d. Protrusion 33b is located between protrusions 33a and 33c. Protrusions 33a, 33b, and 33c correspond to recesses 13a, 13b, and 13c, respectively. Recesses 13a, 13b, and 13c are configured to be able to accommodate protrusions 33a, 33b, and 33c, respectively.

[0061] The multiple grooves 32 include groove 32a and groove 32b. Grooves 32a and 32b extend to surround grooves 31b and 31d. Groove 32a includes a lower left end adjacent to groove 31b in the left-right direction D2, a lower right end adjacent to groove 31d in the left-right direction D2, and an extending portion adjacent to grooves 31b and 31d in the up-down direction D3 and connecting the lower left end and the lower right end. Groove 32b is located outward of groove 32a. Groove 32b extends along groove 32a.

[0062] The mold 1 may include at least one first ferromagnetic body. In the example shown in FIG. 7 , the mold 1 includes ferromagnetic bodies 15a, 15b, and 15c as the at least one first ferromagnetic body. The number of each of the ferromagnetic bodies 15a, 15b, and 15c may be one or more. The ferromagnetic body 15a is embedded in a region between adjacent ribs 11a. The ferromagnetic body 15b is embedded between adjacent ribs 11b and 11c. The ferromagnetic body 15c is embedded between adjacent ribs 11d and 11e.

[0063] The mold 1 may include ferromagnetic material 15d, ferromagnetic material 15e, and ferromagnetic material 15f. The ferromagnetic material 15d is embedded in a region between the protrusion 14a and the rib 11a that are adjacent to each other in the left-right direction D2. The ferromagnetic material 15e is embedded in a region at the bottom of each of the plurality of recesses 13. The ferromagnetic material 15f is embedded in a region of the side surface portion 1c.

[0064] The attachment 2 may include at least one second ferromagnetic body. In the example shown in Fig. 6, the attachment 2 includes ferromagnetic body 35a, ferromagnetic body 35b, and ferromagnetic body 35c as the at least one second ferromagnetic body. The number of each of the ferromagnetic bodies 35a, 35b, and 35c may be one or more. The ferromagnetic body 35a is embedded in a region between adjacent grooves 31a. The ferromagnetic body 35b is embedded between adjacent grooves 31b and 31c. The ferromagnetic body 35c is embedded between adjacent grooves 31d and 31e.

[0065] The attachment 2 may include a ferromagnetic material 35d and a ferromagnetic material 35e. The ferromagnetic material 35d is embedded in a region outside the plurality of grooves 31a in the left-right direction D2. The ferromagnetic material 35e is embedded in a region on the upper surface of each of the plurality of protrusions 33.

[0066] 4 , in step STb, the attachment 2 is placed on the sheet material 200 covering the mold 1 so that the first portion 10 corresponds to the second portion 30. In step STb, the at least one first ferromagnetic body and the at least one second ferromagnetic body are configured to attract each other by magnetic force. For example, the ferromagnetic bodies 15 a, 15 b, and 15 c and the ferromagnetic bodies 35 a, 35 b, and 35 c are magnets configured to attract each other by magnetic force.

[0067] The ferromagnetic bodies 15a and 35a attract the mold 1 and the attachment 2 to each other, thereby suppressing the lifting of the sheet material 200 in the region between adjacent ribs 11a in the left-right direction D2. The ferromagnetic bodies 15b and 35b attract the mold 1 and the attachment 2 to each other, thereby suppressing the lifting of the sheet material 200 in the region between adjacent ribs 11b and 11c in the up-down direction D3. The ferromagnetic bodies 15c and 35c attract the mold 1 and the attachment 2 to each other, thereby suppressing the lifting of the sheet material 200 in the region between adjacent ribs 11d and 11e in the up-down direction D3.

[0068] The attachment 2 may be the first attachment. The manufacturing apparatus 100 may further include an attachment 3 as a second attachment. In the example shown in FIG. 4 or 5, the manufacturing apparatus 100 includes two attachments 3. The attachment 3 includes a corner 4a that protrudes along an interior angle 1e formed by the side surface 1c and the front surface 1a. The manufacturing method MT may include a step STb1. In the step STb1, the attachment 3 is placed on the sheet material 200 hung on the mold 1 so that the corner 4a corresponds to the interior angle 1e. With the attachment 3, the sheet material 200 is pressed against the interior angle 1e by the corner 4a, thereby suppressing lifting of the sheet material 200 at the interior angle 1e.

[0069] The attachment 3 may include at least one second ferromagnetic body. For example, the attachment 3 includes a plurality of ferromagnetic bodies 35f as the at least one second ferromagnetic body. The plurality of ferromagnetic bodies 35f are arranged along the up-down direction D3. The portions of the side surface portion 1c that protrude most forward in the front-to-back direction D1 may be located between adjacent ferromagnetic bodies 35f among the plurality of ferromagnetic bodies 35f.

[0070] Next, step STc is performed. Fig. 8 is a perspective view showing an example of a step of covering the attachment and the sheet material with a cover. Step STc is a step of covering the attachment 2 and the sheet material 200 with the cover 4, thereby forming a closed space between the mold 1 and the cover 4. The cover 4 has a bag shape configured to cover the mold 1, the sheet material 200 covering the mold 1, and the attachment 2 placed on the sheet material 200 covering the mold 1.

[0071] The cover 4 may include an airtight main layer and a reinforcing layer having a higher tensile strength than the main layer. The cover 4 is used in step STc with the reinforcing layer facing inward. In one example, the main layer includes a urethane film. In one example, the reinforcing layer includes a knitted material. The knitted material is formed from nylon, polyester, or acrylic. The main layer and the reinforcing layer may be bonded together. The main layer may be coated onto the reinforcing layer. The cover 4 may also be composed of only the main layer.

[0072] Next, step STd is performed. Step STd is a step of heating the sheet material. FIG. 9 is a perspective view showing an example of a step of heating the sheet material. In the example shown in FIG. 9, heated air is supplied to the closed space. The heated air may contain steam. The temperature of the heated air is set to a temperature at which the sheet material 200 can be thermoformed. For example, air heated by the heating unit 103 is supplied to the inside of the mold 1 via the base 101 by the air supply and exhaust unit 102. The air supplied to the inside of the mold 1 is ejected into the closed space through multiple air vents 1h. The sheet material 200 is heated by the air ejected from the multiple air vents 1h of the mold 1. The mold 1 is heated by the heated air together with the sheet material 200.

[0073] Next, step STe is performed. FIG. 10 is a perspective view showing an example of a step of exhausting air from the closed space. Step STe is a step of exhausting air from the closed space through the multiple air vents 1h and pressing the attachment 2 and the sheet material 200 against the mold 1 with the cover 4, thereby processing the heated sheet material 200 into a shape that conforms to the outer surface 1s. For example, the air supply / exhaust unit 102 exhausts air from the closed space through the multiple air vents 1h and the base 101. The closed space may be evacuated. A vacuum is a state in which a space is filled with gas at a pressure lower than atmospheric pressure. The pressure of the air in the evacuated closed space is lower than atmospheric pressure. The pressure difference between the pressure in the evacuated closed space and atmospheric pressure causes the deformed cover 4 to press the attachment 2. The heated sheet material 200 is pressed against the mold 1 by the attachment 2.

[0074] In step STe, the open end of the cover 4 is closed. For example, the open end of the cover 4 may be closed at a portion connected to the base 101 of the mold 1. The open end of the cover 4 may be closed at a portion connected to the base 101 of the mold 1 by a pair of clips (not shown).

[0075] According to the manufacturing method MT, in step STb, the sheet material 200 is sandwiched between the mold 1 and the attachment 2. After step STb, steps STc, STd, and STe are performed, so that the sheet material 200 is thermoformed while sandwiched between the mold 1 and the attachment 2. The portion of the sheet material 200 that covers the first portion 10 of the mold 1 is thermoformed while sandwiched between the first portion 10 of the mold 1 and the second portion 30 of the attachment 2. The first portion 10 includes a plurality of recesses 13 and protrusions 11. The second portion 30 includes a recess 31 corresponding to the protrusions 11 and a plurality of protrusions 33 corresponding to the plurality of recesses 13, and has rubber elasticity. Therefore, the portion of the sheet material 200 sandwiched between the first portion 10 and the second portion 30 is pressed to conform to the shape of the first portion 10. As a result, the sheet material 200 is molded into a shape that conforms to the plurality of recesses 13 and protrusions 11 of the first portion 10. Therefore, the manufacturing method MT and the manufacturing apparatus 100 improve the formability of the sheet material 200 in the manufacturing process of the seat pad reinforcing cloth S.

[0076] According to the manufacturing method MT and the manufacturing apparatus 100, the protrusion 11 includes a plurality of ribs 11a. The plurality of ribs 11a extend longitudinally in the up-down direction D3 and are adjacent to each other in the left-right direction D2. The recess 31 includes a plurality of grooves 31a extending in the up-down direction D3 so as to be recessed along the plurality of ribs 11a. Therefore, according to the mold 1 and the attachment 2, even in the region between the plurality of ribs 11a where the sheet material 200 is likely to lift from the mold, the sheet material 200 is formed into a shape that conforms to the region.

[0077] According to the manufacturing method MT and the manufacturing apparatus 100, the protrusion 11 includes a plurality of ribs 11b, 11c, 11d, and 11e. The ribs 11b, 11c, 11d, and 11e extend longitudinally in the left-right direction D2 and are adjacent to each other in the up-down direction D3. The recess 31 includes a plurality of grooves 31b, 31c, 31d, and 31e extending in the left-right direction D2 so as to be recessed along the ribs 11b, 11c, 11d, and 11e. Therefore, according to the mold 1 and the attachment 2, the sheet material 200 is molded into a shape that conforms to both the region between the ribs 11a and the region between the ribs 11b, 11c, 11d, and 11e, where the sheet material 200 is likely to float from the mold.

[0078] According to the manufacturing method MT and the manufacturing apparatus 100, the minimum width of one of the ribs 11a in the left-right direction D2 is smaller than the maximum width between adjacent ribs 11a. The minimum width of one of the ribs 11b, 11c in the up-down direction D3 is smaller than the maximum width between adjacent ribs 11b, 11c. The minimum width of one of the ribs 11d, 11e in the up-down direction D3 is smaller than the maximum width between adjacent ribs 11d, 11e. If the width between the ribs is large, the sheet material 200 is likely to float at the base of each rib. According to the manufacturing method MT and the manufacturing apparatus 100, the attachment 2 is placed on the sheet material 200 placed on the mold 1, so that the sheet material 200 is formed into a shape that conforms to the base of each rib, even at the base of each rib where the sheet material 200 is likely to float.

[0079] According to the manufacturing method MT and the manufacturing apparatus 100, the mold 1 includes a ferromagnetic material 15a embedded in a region between the plurality of ribs 11a, a ferromagnetic material 15b embedded in a region between the plurality of ribs 11b and 11c, and a ferromagnetic material 15c embedded in a region between the plurality of ribs 11d and 11e. The attachment 2 includes a ferromagnetic material 35a embedded in a region between the plurality of grooves 31a, a ferromagnetic material 35b embedded in a region between the plurality of grooves 31b and 31c, and a ferromagnetic material 35c embedded in a region between the plurality of grooves 31d and 31e. The ferromagnetic materials 15a, 15b, and 15c and the ferromagnetic materials 35a, 35b, and 35c are configured to attract each other magnetically. Therefore, the sheet material 200 hung on the mold 1 is sandwiched between the plurality of ribs 11a and the plurality of grooves 31a by the attractive forces of the ferromagnetic bodies 15a and 35a, between the plurality of ribs 11b and 11c and the plurality of grooves 31b and 31c by the attractive forces of the ferromagnetic bodies 15b and 35b, and between the plurality of ribs 11d and 11e and the plurality of grooves 31d and 31e by the attractive forces of the ferromagnetic bodies 15c and 35c. According to the manufacturing method MT and the manufacturing apparatus 100, a mark formed by sandwiching between the first and second ferromagnetic bodies may be formed in the thermoformed seat pad reinforcing fabric S. The mark formed by sandwiching between the first and second ferromagnetic bodies may include, for example, a mark consisting of a convex portion or a concave portion that follows the shape of the first ferromagnetic body and / or the second ferromagnetic body.

[0080] The sheet material 200 is placed over the mold 1 by hooking the pocket 22 onto the mold 1. By hooking the pocket 22 onto the mold 1, the positional relationship between the mold 1 and the sheet material 200 is more stable than when the sheet material 200 without the pocket 22 is placed over the mold 1. Furthermore, the pocket 22 has a cutout 27 that exposes the rear surface 1b of the mold 1. The rear surface of the sheet material 200 is thermoformed to fit the first portion 10, which includes a plurality of recesses 13 and protrusions 11, on the front surface of the mold 1. The deformation amount of the rear surface 21 of the sheet material 200 at the front surface 1a of the mold 1 is greater than the deformation amount of the rear surface 21 of the sheet material 200 at the front surface 1a of the mold 1, which does not include the first portion 10. Therefore, tension corresponding to the deformation amount of the rear surface 21 is applied to the pocket 22 attached to the rear surface 21. Because the notches 27 of the pockets 22 open in response to the tension applied to the pockets 22, the pockets 22 do not easily hinder the deformation of the back surface 21 of the sheet material 200. As a result, the sheet material 200 improves the formability of the sheet material 200 in the manufacturing process of the seat pad reinforcing cloth S. Note that the sheet material 200 may be a sheet material that is thermoformed while being covered by a mold 1 having an outer surface 1s that conforms to the seat pad reinforcing cloth S, and on which the attachment 2 is placed while being covered by the mold 1.

[0081] In the sheet material 200, the notches 27 may be continuous with the opening edge 23 that defines the opening of the pocket 22. In this sheet material 200, the notches 27 open due to tension applied to the opening edge 23 of the pocket 22, so deformation of the back surface 21 of the sheet material 200 is even less likely to be inhibited.

[0082] The manufacturing method MT may further include a process STf, a process STg, and a process STg1. The manufacturing apparatus 100 may further include a processing machine 5. FIG. 11 is a perspective view showing an example of a process for removing a cover and an attachment. FIG. 12 is a front view of a seat pad reinforcing cloth according to one embodiment. Hereinafter, the process STf, the process STg, the process STg1, and the processing machine 5 will be described in detail with reference to FIGS. 11 and 12 .

[0083] Process STf is performed following process STe. In process STf, the cover 4 and the attachment 2 are removed. In process STf, first, the cover 4 covering the attachment 2 and the sheet material 200 is removed, and then the attachment 2 placed on the sheet material 200 covering the mold 1 is removed. Figure 11 shows the mold 1 and the sheet material 200 from which the cover 4 and the attachment 2 have been removed.

[0084] Next, process STg is performed. In process STg, a plurality of slits 41s are formed in the portion of the sheet material 200 covering the mold 1 that corresponds to the side surface portion 1c, with the vertical direction D3 as the longitudinal direction and aligned along the vertical direction D3. The manufacturing apparatus 100 may further include a processing machine 5 configured to form the plurality of slits 41s. In one example, the processing machine 5 is a laser processing machine. The portion of the sheet material 200 covering the mold 1 that corresponds to the side surface portion 1c is the portion of the sheet material 200 that covers the side surface portion 1c of the mold 1.

[0085] 12, three slits are formed as the plurality of slits 41s in a portion of the sheet material 200 that covers one side surface portion 1c of the mold 1. Two slits are formed as the plurality of slits 41s in a portion of the sheet material 200 that covers the other side surface portion 1c of the mold 1. The minimum length of the plurality of slits 41s in the vertical direction D3 is greater than the maximum length of the area between the plurality of slits 41s in the vertical direction D3. The total length of the plurality of slits 41s in the vertical direction D3 is equal to or greater than half the length of the side portion Sc in the vertical direction D3.

[0086] According to the manufacturing method MT and the manufacturing apparatus 100, a plurality of slits 41s are formed in the side portion Sc of the seat pad reinforcing cloth S, aligned along the vertical direction D3. A single long slit corresponding to the entirety of the plurality of slits 41s is likely to open when the seat pad reinforcing cloth S and the seat pad are joined. The plurality of slits 41s aligned along the vertical direction D3 in the side portion Sc of the seat pad reinforcing cloth S are less likely to open when the seat pad reinforcing cloth S and the seat pad are joined because each of the plurality of slits 41s is shorter than the single long slit. Therefore, the manufacturing method MT and the manufacturing apparatus 100 facilitate joining the seat pad reinforcing cloth S and the seat pad.

[0087] Subsequently, step STg1 is performed. Step STg1 may be performed subsequent to step STf. In step STg1, in the portion of the sheet material 200 covering the mold 1 corresponding to the front surface 1a, openings may be formed in at least one of the bottom surface of the recess corresponding to the first recess and the top surface of the protrusion corresponding to the first protrusion. In the example shown in FIG. 12, in the portion corresponding to the front surface 1a, openings are formed in the portion corresponding to the protrusion 11 of the first portion 10. For example, among the protrusions 41 of the sheet material 200 corresponding to the protrusions 11, a plurality of openings 42 are formed in the top surfaces of a plurality of protrusions 41a corresponding to a plurality of ribs 11a.

[0088] According to the manufacturing method MT and the manufacturing apparatus 100, the opening 42 is formed with the sheet material 200 facing the mold 1, so that the opening 42 can be easily formed on the upper surface of the convex portion of the back portion Sa of the seat pad reinforcing cloth S.

[0089] A step of forming openings may be performed in portions of the sheet material 200 covering the mold 1 that correspond to the interior angle 1e between the front surface 1a and the side surface 1c. In the example shown in Fig. 12, a plurality of openings 43 are formed in portions of the sheet material 200 covering the mold 1 that correspond to the interior angle 1e. According to the manufacturing method MT and the manufacturing apparatus 100, the openings 43 are formed in a state where the sheet material 200 faces the mold 1, so that the openings 43 can be easily formed in the interior corners Se of the seat pad reinforcing cloth S.

[0090] Although various exemplary embodiments have been described above, the present disclosure is not limited to the above embodiments, and various omissions, substitutions, and modifications may be made.

[0091] 1... Mold, 1a... Front part, 1b... Rear part, 1c... Side part, 1e... Inner corner, 1h... Ventilation hole, 1s... Outer surface, 2, 3... Attachment, 4... Cover, 4a... Corner part, 5... Processing machine, 10... First part, 11, 12, 12a, 12b, 14, 14a, 14b, 33, 33a, 33b, 33c, 41, 41a... Convex portion, 11a, 11b, 11c, 11d, 11e... Rib, 31a, 31b, 31c, 31d, 31e, 32, 32a, 32b...groove, 13, 13a, 13b, 13c, 31, 31a, 32...recess, 21...back, 22...pocket, 23...opening edge, 27...cutout, 30...second part, 41s...slit, 42, 43...opening, 100...manufacturing apparatus, 200...sheet material, D1...direction, D2...left-right direction, D3...up-down direction, MT...manufacturing method, S...seat pad reinforcing cloth, Sa...back part, Sc...side part.

Claims

1. A method for manufacturing a seat pad reinforcing cloth using a mold having an outer surface that conforms to the seat pad reinforcing cloth, wherein the mold has a first portion including at least one of a first recess and a first protrusion, a front portion corresponding to the back of the seat pad reinforcing cloth, a rear portion facing the front portion in the front-to-rear direction, and a plurality of ventilation holes communicating from the outer surface to the inside of the mold, (a) a step of covering the mold with a sheet material, (b) a step of placing an attachment having a second portion that conforms to the first portion on the sheet material that has been covered over the mold so that the first portion corresponds to the second portion, the second portion including at least one of a second protrusion that corresponds to the first recess and a second recess that corresponds to the first protrusion, and having rubber elasticity, (c) a step of covering the attachment and the sheet material with a cover to form an enclosed space between the mold and the cover, (d) a step of heating the sheet material, (e) exhausting air from the closed space through the plurality of air vents and using the cover to press the attachment and the sheet material against the mold, thereby processing the heated sheet material into a shape that conforms to the outer surface.

2. A method for manufacturing a seat pad reinforcing cloth as described in claim 1, wherein at least one of the first convex portion and the second convex portion is a plurality of ribs extending with a first direction perpendicular to the front-to-rear direction as its longitudinal direction, and includes the plurality of ribs adjacent to each other in a second direction perpendicular to the front-to-rear direction and the first direction, and at least one of the first recessed portion and the second recessed portion is a plurality of grooves extending with the first direction as its longitudinal direction so as to be recessed along the plurality of ribs, and includes the plurality of grooves adjacent to each other in the second direction.

3. A method for manufacturing a seat pad reinforcing fabric as described in claim 2, wherein the plurality of ribs are a plurality of first ribs, the plurality of grooves are a plurality of first grooves, at least one of the first convex portion and the second convex portion is a plurality of second ribs extending with the second direction as its longitudinal direction, and includes the plurality of second ribs adjacent to each other in the first direction, and at least one of the first recessed portion and the second recessed portion is a plurality of second grooves extending with the second direction as its longitudinal direction so as to be recessed along the plurality of second ribs, and includes the plurality of second grooves adjacent to each other in the first direction.

4. A method for manufacturing a seat pad reinforcing fabric as described in claim 2, wherein the minimum width in the second direction of one of the plurality of ribs is smaller than the maximum width in the second direction between adjacent ribs among the plurality of ribs.

5. A method for manufacturing a seat pad reinforcing fabric as set forth in any one of claims 2 to 4, wherein the mold includes at least one first ferromagnetic body embedded in a region between adjacent ribs of the plurality of ribs of the first convex portion and at least one between adjacent grooves of the plurality of grooves of the first concave portion, and the attachment includes at least one second ferromagnetic body embedded in a region between adjacent ribs of the plurality of ribs of the second convex portion and at least one between adjacent grooves of the plurality of grooves of the second concave portion, and the at least one first ferromagnetic body and the at least one second ferromagnetic body are configured to attract each other by magnetic force in (b).

6. A method for manufacturing a seat pad reinforcing cloth as described in any one of claims 1 to 4, wherein the sheet material includes a back surface configured to be formed as the back portion of the seat pad reinforcing cloth by thermoforming, and a pocket formed on the back surface so as to define a space between the back surface and the pocket, the pocket being configured to be hooked onto the mold and facing the rear surface portion, and in (a), the pocket is hooked onto the mold.

7. A method for manufacturing a seat pad reinforcing cloth as described in any one of claims 1 to 4, wherein the mold further includes side portions corresponding to the sides of the seat pad reinforcing cloth, the side portions being adjacent to the front portion in a left-right direction perpendicular to the front-to-rear direction and protruding forward of the front portion in the front-to-rear direction, the attachments being first attachments, and further comprising: (b1) a step of placing a second attachment including a corner portion protruding along an interior angle formed by the side portion and the front portion on the sheet material hung on the mold so that the interior angle corresponds to the corner portion.

8. A method for manufacturing a seat pad reinforcing cloth as claimed in any one of claims 1 to 4, wherein the mold further includes side portions corresponding to the sides of the seat pad reinforcing cloth, the side portions being adjacent to the front portion in a left-right direction perpendicular to the front-rear direction and protruding forward of the front portion in the front-rear direction, and the method further includes the steps of: (f) removing the cover and the attachment; and (g) forming, in the portions of the sheet material placed over the mold corresponding to the side portions, a plurality of slits whose longitudinal direction is in a vertical direction perpendicular to the front-rear direction and the left-right direction and which are aligned along the vertical direction.

9. A method for manufacturing a seat pad reinforcing cloth described in any one of claims 1 to 4, further comprising the steps of: (f) removing the cover and the attachment; and (g1) forming an opening in at least one of the bottom surface of a recess corresponding to the first recess and the top surface of a protrusion corresponding to the first protrusion in a portion of the sheet material placed over the mold corresponding to the first portion of the front surface.

10. An apparatus for manufacturing a seat pad reinforcing cloth, comprising: a mold having an outer surface that conforms to the seat pad reinforcing cloth; and an attachment attached to a sheet material placed over the mold, wherein the mold has a first portion including at least one of a first recess and a first protrusion, and includes a front portion corresponding to the back of the seat pad reinforcing cloth, a rear portion facing the front portion in the front-to-rear direction, and a plurality of air holes communicating from the outer surface to the inside of the mold, and the attachment includes at least one of a second protrusion corresponding to the first recess and a second recess corresponding to the first protrusion, and includes a second portion having rubber elasticity.

11. A manufacturing device for a seat pad reinforcing cloth as described in claim 10, wherein at least one of the first convex portion and the second convex portion is a plurality of ribs extending with a first direction perpendicular to the front-to-rear direction as its longitudinal direction, and includes the plurality of ribs adjacent to each other in a second direction perpendicular to the front-to-rear direction and the first direction, and at least one of the first recessed portion and the second recessed portion is a plurality of grooves extending with the first direction as its longitudinal direction so as to be recessed along the plurality of ribs, and includes the plurality of grooves adjacent to each other in the second direction.

12. A manufacturing device for a seat pad reinforcing cloth as described in claim 11, wherein the plurality of ribs are a plurality of first ribs, the plurality of grooves are a plurality of first grooves, at least one of the first convex portion and the second convex portion are a plurality of second ribs extending with the second direction as their longitudinal direction, and include the plurality of second ribs adjacent to each other in the first direction, and at least one of the first recessed portion and the second recessed portion are a plurality of second grooves extending with the second direction as their longitudinal direction so as to be recessed along the plurality of second ribs, and include the plurality of second grooves adjacent to each other in the first direction.

13. The manufacturing device for a seat pad reinforcing cloth according to claim 11, wherein the minimum width in the second direction of one of the plurality of ribs is smaller than the maximum width in the second direction between adjacent ribs among the plurality of ribs.

14. A manufacturing device for a seat pad reinforcing cloth as described in any one of claims 11 to 13, wherein the mold includes at least one first ferromagnetic body embedded in a region between adjacent ribs of the plurality of ribs of the first convex portion and at least one between adjacent grooves of the plurality of grooves of the first concave portion, and the attachment includes at least one second ferromagnetic body embedded in a region between adjacent ribs of the plurality of ribs of the second convex portion and at least one between adjacent grooves of the plurality of grooves of the second concave portion, and the at least one first ferromagnetic body and the at least one second ferromagnetic body are configured to attract each other by magnetic force.

15. A manufacturing device for a seat pad reinforcing cloth as described in any one of claims 11 to 13, wherein the mold further includes side portions corresponding to the sides of the seat pad reinforcing cloth, the side portions being adjacent to the front portion in a left-right direction perpendicular to the front-to-rear direction and protruding forward of the front portion in the front-to-rear direction, and the attachment is a first attachment, and further includes a second attachment including a corner portion protruding along an interior angle formed by the side portion and the front portion.

16. A manufacturing device for a seat pad reinforcing cloth as claimed in any one of claims 11 to 13, wherein the mold further includes side portions corresponding to the sides of the seat pad reinforcing cloth, the side portions being adjacent to the front portion in a left-right direction perpendicular to the front-rear direction and protruding forward of the front portion in the front-rear direction, and further comprising a processing machine configured to form, in the portion of the sheet material placed over the mold corresponding to the side portions, a plurality of slits whose longitudinal direction is in a vertical direction perpendicular to the front-rear direction and the left-right direction and which are aligned along the vertical direction.

17. A manufacturing device for a seat pad reinforcing cloth as claimed in any one of claims 11 to 13, further comprising a processing machine configured to form an opening in at least one of the bottom surface of a recess corresponding to the first recess and the top surface of a protrusion corresponding to the first protrusion, in a portion of the sheet material placed over the mold that corresponds to the first portion of the front surface.

18. A sheet material that is thermoformed while being placed over a mold having an outer surface that conforms to a seat pad reinforcing fabric, wherein the mold has a portion including at least one of a recess and a protrusion, and includes a front portion that corresponds to the back portion of the seat pad reinforcing fabric, a rear portion that faces the front portion in the front-to-rear direction, and a plurality of ventilation holes that communicate from the outer surface to the inside of the mold, wherein the sheet material comprises: a back portion configured to be formed as the back portion of the seat pad reinforcing fabric by thermoforming, and a pocket formed on the back portion to define a space between the back portion and the pocket, the pocket configured to be hooked onto the mold and to face the rear portion, and wherein a cutout is formed in the pocket configured to expose the rear portion of the mold.

19. The sheet material according to claim 18, wherein the notch is continuous with an open edge that defines the opening of the pocket.

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