JP2005237491A - Pad for seat, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a pad for seat which is excellent in formability, appearance quality and surface touch feeling by solving a failure in the case of sewing a reinforcing cloth. <P>SOLUTION: In the manufacturing method of the pad 10 for the seat, the reinforcing cloth 14 provided with a sewing part 40 is mounted inside a mold 50, and by injecting, foaming and filling a foaming stock solution U in the mold 50, a pad body 12 composed of soft foam is foamed and the reinforcing cloth 14 is integrated on the back surface. At the time of foaming, the outlet seam 22b of a cloth part 22 positioned on the upstream side of the flowing direction F of the foaming stock solution U is arranged on the side of the foaming stock solution U and the outlet seam 26a of the cloth part 26 positioned on the downstream side of the flowing direction F is arranged on the side of the mold 50 respectively in the sewing part 40 of the reinforcing cloth 14, and the foaming stock solution U is foamed and filled inside the mold 50. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a seat pad used as a seat cushion material for a vehicle or the like and a method for manufacturing the same.

In general, a seat pad used as a seat cushion material for a vehicle or the like is a molded product of a flexible flexible foam such as a flexible polyurethane foam. Such a seat pad is configured as a seat by being assembled to a mounting steel material such as a spring, a frame, and a pipe, but abnormal noise is generated due to vibration between the pad and the mounting steel material during seating. Or there was a problem of damage. Therefore, in order to prevent the occurrence of such abnormal noise or to protect and strengthen from damage, a reinforcing fabric such as a nonwoven fabric is integrated as a backing material on the back of the pad body made of flexible foam by foam molding of the flexible foam. (For example, refer to Patent Documents 1 to 3 below).
JP-A-6-171002 JP-A-6-171003 JP 2000-62061 A

  This type of reinforcing cloth needs to be integrated along the shape of the back surface of the pad main body. For this purpose, it is preferable to sew the reinforcing cloth in advance to obtain a three-dimensional shape. However, when the reinforcing fabric is sewed, during foam molding, the seam allowance at the sewn part interferes with the flow of the foaming stock solution, or molding failure occurs, or the seam allowance stands up due to the flow of the foaming stock solution. When it hardens in a state, it may appear on the pad surface or the soft touch feeling on the pad surface may be impaired.

  In particular, back pads used for the backrest of automobile seats may have an inward overhang on the back of the pad body. In such a case, noise is prevented even on the inner surface of the overhang. Therefore, it is required to integrate the reinforcing cloth, and it is necessary to sew the reinforcing cloth into a bag shape. In such a case, if the sewing part is configured without considering the liquid flow of the foaming stock solution, the foaming stock solution does not smoothly flow to the overhanging part due to the seam allowance, and the standing seam allowance is relatively thin. It tends to cause poor quality such as appearing as a hard core on the outer surface of the glass or impairing the softness of the surface.

  The present invention has been made in view of the above points, and eliminates problems in the case where a joint portion by sewing or the like is provided on a reinforcing cloth, and is excellent in formability, appearance quality, and surface touch feeling and It aims at providing the manufacturing method.

  The method for manufacturing a pad for a sheet according to the present invention includes a pad body made of a flexible foam by mounting a reinforcing cloth having a joint portion in a mold, and injecting a foaming stock solution into the mold to perform foam filling. A method for manufacturing a pad for a sheet that is foam-molded and has the reinforcing cloth integrated with the back surface thereof, wherein the cloth is positioned upstream of the foaming stock solution flow direction at the joint of the reinforcing cloth during the foam molding. The foaming stock solution is foam-filled in the mold so that the joining allowance of the part is arranged on the foaming stock solution side and the joining allowance of the cloth part located on the downstream side in the flow direction is arranged on the molding die side, respectively. It is characterized by making it.

  Thus, in the joint part of the reinforcing cloth, the joint part (free end) of the cloth part located on the upstream side in the flow direction of the foaming stock solution is overlapped with the joint part of the cloth part located on the downstream side so that it becomes the foaming stock solution side. By joining together and mounting in the mold, the flow of the foaming stock solution is not hindered by the joining margin of the joint portion of the reinforcing fabric when the foaming stock solution is filled, thereby improving the moldability. Further, in this case, since the joining allowance does not stand up due to the flow of the foaming stock solution, the above-described problems of poor appearance and surface touch can be solved.

  In the present invention, the pad body is composed of a pad main body part and an inwardly extending part integrally provided on three side parts including both sides on the back side of the pad main body part, The reinforcing cloth may be formed in a bag shape and integrated so as to cover the back surface of the pad main body portion and the inner surface of the overhang portion.

  Further, in this case, the reinforcing cloth is integrally formed on the back surface of the pad main body part, and the inner surface of the overhanging part on both side parts of the pad main body is integrally extended from both side parts thereof. Side surfaces of the cloth body, a cloth upper surface part integrally extending from the upper side of the cloth main body part, and an extension of the protruding part at the upper side part of the pad main body integrally extending from the cloth upper surface part. It consists of a cloth rear surface part that is integrated with the inner surface, and joins the opposite sides of the cloth side part and the cloth upper surface part, and joins the opposite sides of the cloth side part and the cloth rear surface part. In this case, the reinforcing cloth is formed into a bag shape, and at this time, the cloth upper surface portion is arranged so that the joint margin of the cloth side surface portion is arranged on the outer side at the joint portion between the cloth side surface portion and the cloth upper surface portion. And overlapped with the joint allowance, and at the joint between the cloth side surface and the cloth rear surface It is preferable that the bonding margins of the fabric side portion is bonded to overlap and bonding margins of the cloth rear panel to be disposed on the outside.

  Furthermore, the side which becomes the joining margin of the cloth upper surface part may be formed in a stepped shape so as to protrude outward with respect to the side which becomes the joining margin of the cloth rear surface part. In this case, when joining the cloth side surface portion and the cloth upper surface portion, the joining allowance of the cloth upper surface portion protrudes in a stepped shape, which makes it easy to perform the joining work as a mark and create a three-dimensional shape. It becomes easy.

  The present invention also provides a sheet pad obtained by the above-described manufacturing method, that is, the sheet pad according to the present invention includes a pad body made of a flexible foam, and the flexible foam on the back surface of the pad body. A pad for a sheet comprising a reinforcing cloth integrated by foam molding, wherein the reinforcing cloth has a joint, and the joint is located upstream of the flow direction of the flexible foam during foam molding. The joining allowance is overlapped with the joining allowance of the cloth part located on the downstream side in the flow direction so that the joining allowance of the cloth part is on the flexible foam side.

  Further, as a more specific aspect, the seat pad according to the present invention is an inwardly provided pad main body, and inwardly provided integrally on three sides on the upper and left and right sides of the back surface of the pad main body. Reinforcement cloth integrally formed by foam molding of the flexible foam so as to cover the back surface of the pad main body and the inner side surface of the overhanging portion, which is formed in a bag shape, and is made of a soft foam having an overhanging portion. A pad for a sheet, wherein the reinforcing cloth is integrally formed on a back surface of the pad main body, and both sides of the pad main body are integrally extended from both sides thereof. Of the pad main body, a cloth upper surface part integrally extended from the upper side of the cloth main body part, and a pad upper surface part of the pad main body which is integrally extended from the cloth upper surface part. The tension on the upper side A fabric rear surface portion integrated with the inner side surface of the take-out portion, joining opposite sides of the fabric side surface portion and the fabric upper surface portion, and opposing sides of the fabric side surface portion and the fabric rear surface portion It is formed in a bag shape by joining together, and in the joint part between the cloth side surface part and the cloth upper surface part, the joint allowance of the cloth upper surface part so that the joint allowance of the cloth side surface part is arranged on the outside The cloth side surface portion and the cloth rear surface portion are joined by being overlapped and joined with the cloth rear surface portion joining margin so that the joint margin of the cloth side surface portion is arranged outside. It is characterized by this.

  In the above-described present invention, it is preferable that the joining is by sewing, but the joining means is not limited to sewing, and the overlapped cloths are joined together using a fixing tool such as a stapler or a tag pin. You can also.

  As described above, according to the present invention, in the seat pad provided with the reinforcing cloth for preventing abnormal noise on the back surface of the pad main body, the problem in the case where the joint part by sewing or the like is provided on the reinforcing cloth is solved. The moldability, appearance quality and surface touch feeling can be improved.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  1 is a perspective view of a pad 10 for a sheet according to an embodiment of the present invention, FIG. 2 is a sectional view of the pad 10, FIG. 3 is a development view of a reinforcing cloth 14 used for the pad 10, and FIGS. The perspective view after the sewing, FIGS. 6 to 7 are cross-sectional views of the pad 10 during foam molding.

  As shown in FIG. 1, this seat pad 10 is a back pad used for a backrest portion of a front seat of an automobile, for example, and includes a pad main body 12 made of a flexible polyurethane foam and a reinforcing layer laminated and integrated on the back surface thereof. It consists of cloth 14 and is assembled to a mounting steel material (not shown) such as a frame.

  The pad main body 12 has an inward flange-like overhang for frame mounting integrally provided on three sides of the pad main body portion 16 constituting the backrest and the upper side and the left and right sides on the back side. It consists of the part 18, and has comprised the outline bag shape as a whole. A through hole 19 for mounting a headrest (not shown) is provided on the upper surface of the pad main body 12.

  The reinforcing cloth 14 is sewn in a bag shape as shown in FIG. 4, and is integrally formed by foaming polyurethane foam so as to cover the back surface of the pad main body portion 16 and the inner side surface of the overhang portion 18 as shown in FIG. It has become. The reinforcing cloth 14 can be used without any particular limitation as long as it has an appropriate air permeability and can prevent the polyurethane foam from oozing out during molding. These laminated composites can be used.

  The shape of the base fabric constituting the reinforcing fabric 14 is as shown in FIG. 3, and is extended integrally from the substantially trapezoidal fabric main body 20 integrated on the back surface of the pad main body 16 and both sides thereof. The cloth side surface portion 22 integrated with the inner side surfaces of the overhang portions 18a, 18a on both side portions of the pad main body 12, and the substantially rectangular cloth upper surface portion 24 integrally extending from the upper side of the cloth main body portion 20, The cloth rear surface portion 26 extends integrally from the cloth upper surface portion 24 and is integrated with the inner surface of the overhang portion 18b on the upper side portion of the pad main body 12. The cloth upper surface portion 24 is provided with a through hole 36 for a headrest at a position relative to the through hole 19 of the pad main body 12.

  On the left and right sides of the cloth upper surface portion 24 and the left and right sides of the fabric rear surface portion 26, sewing margins 24a and 26a are provided, respectively. As shown in the drawing, the seam allowance 24a of the cloth upper surface portion 24 is formed to protrude outward by a predetermined dimension with respect to the seam allowance 26a of the fabric rear surface portion 26 via a step portion 28. Further, a seam allowance 22a is formed on the upper side of the cloth side surface portion 22 facing the seam allowance 24a of the fabric upper surface portion 24, and a seam allowance 22b is formed on the side of the fabric side surface portion 22 facing the seam allowance 26a of the fabric rear surface portion 26. ing. A V-shaped cutout 30 is provided at the boundary between the seams 22a and 22b so that the seams 22a and 22b can be easily laid after sewing. Furthermore, in order to make it easy to follow the back surface shape of the pad main body 12 at the lower side of the cloth side surface portion 22, a notch 32 having a predetermined length is provided, and a three-dimensional shape is produced using the notch 32 portion. A V-shaped notch 34 is provided as a mark for sewing.

  When sewing the reinforcing fabric 14 using this base fabric, first, the opposing sides 22a and 24a of the fabric side surface portion 22 and the fabric upper surface portion 24 are overlapped so that the sides are parallel to each other. Suture. At that time, the seam allowance 22a of the cloth side surface portion 22 is turned up and the seam allowance 24a of the cloth upper surface portion 24 is overlapped with the seam allowance 24a. However, since the seam allowance 24a of the fabric upper surface portion 24 protrudes in a step shape as described above, It is easy to perform sewing work as a mark, and it is easy to create a three-dimensional shape. Then, as shown in FIG. 5, the sewing 38 is performed so that the seam allowance 22a of the cloth side surface portion comes out of the bag shape.

  Next, the opposing sides 22b and 26a of the cloth side face portion 22 and the cloth rear face portion 26 are stitched together. At that time, sewing 40 is performed with the seam allowance 22b of the cloth side face portion 22 facing up and the seam allowance 26a of the cloth rear face portion 26. As a result, as shown in FIG. 5, the sewing 40 is performed so that the seam allowance 22 b of the cloth side surface portion is exposed outside the bag shape.

  Thereafter, the two cloth portions 32a and 32b cut by the cut 32 are overlapped and stitched. At that time, the other cloth part 32b is overlapped on the cloth part 32a on the notch 34 side and is sewn 42. As a result, as shown in FIG. 4, the sewing 42 is performed so that the seam allowance of the cloth portion 32 b on the side close to the cloth main body portion 20 is outside the bag shape. The sewing 42 can also be performed prior to the sewing 38, 40.

  Thus, the reinforcing cloth 14 is sewn into a bag shape. In addition, it is preferable that the reverse stitching is performed once or more at the start point and the end point of each sewing 38, 40, 42.

  The reinforcing cloth 14 sewed in this manner is mounted in a molding die 50 shown in FIGS. 6 and 7 and laminated and integrated on the back surface of the pad main body 12 by foam molding.

  As shown in the figure, the mold 50 is rotatable via a lower mold 52 that is recessed so as to mold the surface side portion of the pad main body 12 and a hinge portion 54 that is disposed on one side of the lower mold 52. And an upper die 56 that opens and closes the upper surface opening of the lower die 52. The upper die 56 is a die that molds the back surface side of the pad main body 12, and a cavity 58 that is a foaming space corresponding to the pad shape is formed between the lower die 52 and the lower die 52 by closing the upper surface opening of the lower die 52. . The upper die 56 is provided with a core die 60 for molding the overhanging portion 18. The core mold 60 is provided so as to be movable up and down by a driving device 62 provided on the upper mold 56. When the core mold 60 is moved downward by the driving device 56, the core mold 60 is detached from the upper mold 56 and is used as a mold. It is designed to be opened.

  When foam-molding the sheet pad 10 using the molding die 50, first, the reinforcing cloth 14 sewn as described above is mounted in the molding die 50. Specifically, as shown in FIGS. 6 and 7, the reinforcing cloth 14 having a bag shape is placed on the core mold 60 and fixed with a pin 64 or the like, and is set on the upper mold 56 side in the cavity 58.

  Next, after injecting the polyurethane foam foaming stock solution U into the cavity 58 using an unillustrated injector, the upper mold 56 is closed to seal the cavity 58. The foaming stock solution U is preferably poured into the lower mold 52 as evenly as possible. Thereby, the foaming stock solution U fills the cavity 58 while foaming.

  At this time, in the present embodiment, since the reinforcing cloth 14 sewn in a bag shape as described above is used, the flow direction of the foaming undiluted solution U is increased in each of the sewing portions 38, 40, 42 of the reinforcing cloth 14. The seam allowance of the cloth part located on the upstream side is arranged on the foaming stock solution U side, and the seam allowance of the cloth part located on the downstream side in the flow direction is arranged on the molding die 50 side. In this state, the foaming stock solution U is filled. It will be done. Specifically, in the case of the sewing portion 40 of the seam allowance 22b of the cloth side surface portion and the seam allowance 26a of the fabric rear surface portion shown in FIG. 8, the seam allowance 22b of the fabric side surface portion 22 located on the upstream side in the flow direction F of the foaming stock solution U. Are overlapped with the seam allowance 26a of the cloth rear surface portion 26 located on the downstream side in the flow direction F so as to be located on the foaming stock solution U side. Therefore, since the seam allowance 22b on the side in contact with the foaming stock solution U in the sewing part 40 is directed in the same direction as the flow direction F, the seam allowance 22b of the sewn part 40 of the reinforcing fabric 14 is filled with the seam allowance 22b of the reinforcing cloth 14 during foam filling. The flow is not hindered, and the seam allowance 22b does not stand up due to the flow of the foaming stock solution U. The same applies to the other sewing parts 38 and 42.

  Then, by foaming and filling the foaming stock solution U in the cavity 58 in this way, the pad body 12 made of polyurethane foam is foam-molded, and the reinforcing cloth 14 is integrated on the back surface thereof. After the molding, the upper die 56 is opened, the core die 60 is further detached from the upper die 56, the die is opened, and then the mold is removed, whereby the sheet pad 10 shown in FIGS.

  Although the obtained pad 10 for sheet | seat is what formed the reinforcement cloth 14 in the shape of a bag, since each sewing part 38,40,42 was comprised as mentioned above, at the time of foam molding, the reinforcement cloth 14 of the reinforcement cloth 14 is comprised. The flow of the foaming stock solution U is not hindered by the seam allowance of the sewn portion, and the sewing allowance 22b does not stand up due to the flow of the foaming stock solution U, so that the moldability can be ensured and the appearance defect and surface touch can be ensured. There is no problem of defects. Therefore, in the back pad, it is possible to provide a sheet pad having an excellent noise prevention effect without impairing moldability, appearance quality, and surface touch feeling.

  The present invention is particularly effective when the reinforcing cloth is sewn in a bag shape as described above. However, the present invention is not limited to this, and is also applicable to the case where a reinforcing cloth subjected to various types of sewing is used. be able to. Further, the present invention can be applied not only to sewing but also to joining using a fixing tool such as a stapler or a tag pin (a pin generally used for fastening a tag such as a plastic stapler).

It is a perspective view of the pad for sheets concerning one embodiment of the present invention. It is the II-II sectional view taken on the line of FIG. It is an expanded view of the reinforcement cloth used for the pad for the sheet | seat. It is a perspective view after sewing of the reinforcement cloth. It is a principal part expansion perspective view of the reinforcement cloth. It is sectional drawing of the shaping | molding die of the pad for the sheets. It is the VII-VII sectional view taken on the line of FIG. It is a principal part expanded sectional view at the time of foam molding of the pad for sheets.

Explanation of symbols

10 …… Seat pad 12 …… Pad body 14 …… Reinforcement cloth 16 …… Pad main part 18 …… Overhang part 20 …… Cloth main part 22 …… Cloth side face part 22a, 22b, 24a, 26a …… Sewing allowance ( Bonding allowance)
24 …… Cloth upper surface portion 26 …… Cloth rear surface portion 38, 40, 42 …… Sewing portion (joint portion)
50 ... Mold

Claims (9)

By attaching a reinforcing cloth having a joint in the mold and injecting the foaming stock solution into the mold and filling it with foam, the pad body made of flexible foam is foam-molded and the reinforcing cloth is integrated on the back surface. A method for manufacturing a pad for a sheet,
At the time of the foam molding, in the joint portion of the reinforcing cloth, the joint margin of the cloth portion located on the upstream side in the flow direction of the stock foam solution is joined to the foam stock solution side and the cloth portion located on the downstream side in the flow direction. A method for producing a pad for a sheet, characterized in that the foaming stock solution is foam-filled in the molding die such that a margin is arranged on the molding die side. The pad main body is composed of a pad main body part and an inwardly extending part integrally provided on three side parts including both sides on the back side of the pad main body part,
2. The method for manufacturing a pad for a sheet according to claim 1, wherein the reinforcing cloth is formed in a bag shape and integrated so as to cover a back surface of the pad main body and an inner surface of the overhanging portion. The reinforcing cloth is integrated with the cloth main body part integrated with the back surface of the pad main body part, and integrated with the inner side surface of the overhanging part at both side parts of the pad main body. A cloth side surface part, a cloth upper surface part integrally extending from the upper side of the cloth main body part, and an inner side surface of the overhanging part integrally extending from the upper surface part of the pad main body Made of cloth rear surface part,
Joining the opposite sides of the cloth side surface portion and the cloth upper surface portion, and forming the reinforcing cloth into a bag shape by joining the opposite sides of the cloth side surface portion and the cloth rear surface portion, At the time of joining the cloth side surface portion and the cloth top surface portion, the cloth side surface portion is joined to the cloth top surface portion so that the joint allowance of the cloth side surface portion is arranged on the outside. The pad for sheet according to claim 2, wherein at the joint portion with the fabric rear surface portion, the joint is overlapped with the joint margin of the fabric rear surface portion so that the joint margin of the fabric side surface portion is arranged outside. Manufacturing method.   4. The sheet according to claim 3, wherein a side of the cloth upper surface portion that forms the joining margin is formed in a stepped shape so as to project outward with respect to the side of the cloth rear surface portion that serves as the joining margin. A method for manufacturing a pad.   The method for manufacturing a pad for a sheet according to any one of claims 1 to 4, wherein the joining is performed by sewing. A pad for a sheet comprising a pad body made of a flexible foam and a reinforcing cloth integrated by foam molding of the flexible foam on the back surface of the pad body,
The reinforcing cloth includes a joint portion, and the joint portion has the joint margin so that the joint margin of the cloth portion located on the upstream side in the flow direction of the flexible foam at the time of foam molding is the soft foam side. A pad for a sheet, which is formed by being overlapped with a joining margin of a cloth portion located on the downstream side in the flow direction. A pad body made of a flexible foam, comprising a pad main body, and inwardly extending portions integrally provided on the three sides of the upper and left and right sides of the back surface of the pad main body;
A sheet pad comprising a reinforcing cloth integrated by foam molding of the flexible foam so as to cover the back surface of the pad main body portion and the inner surface of the overhang portion formed in a bag shape,
The reinforcing cloth is integrated with the cloth main body part integrated with the back surface of the pad main body part, and integrally with the inner side surface of the overhanging part at both side parts of the pad main body. A cloth side surface part, a cloth upper surface part integrally extending from the upper side of the cloth main body part, and an inner side surface of the overhanging part integrally extending from the upper surface part of the pad main body A cloth rear surface portion, and the opposite sides of the cloth side surface portion and the cloth upper surface portion are bonded together, and the opposite sides of the cloth side surface portion and the cloth rear surface portion are bonded together to form a bag. Formed into
In the joint portion between the cloth side surface portion and the cloth upper surface portion, the cloth side surface portion and the cloth side surface portion The pad for sheets according to claim 1, wherein at the joint portion with the fabric rear surface portion, the fabric side surface portion is joined with being overlapped with the joint rear surface portion so that the joint margin of the fabric side surface portion is arranged outside.   The sheet according to claim 7, wherein the cloth upper surface portion is formed in a step shape so that a side of the cloth rear surface portion protrudes outward with respect to the side of the cloth rear surface portion serving as the joint margin. pad.   The seat pad according to any one of claims 6 to 8, wherein the joining is performed by sewing.

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