JP7348732B2 - Vehicle cushion pad and its manufacturing method - Google Patents

Description

The present invention relates to a vehicle cushion pad constituting a vehicle seat and a method for manufacturing the same.

Cushion pads that make up the seats of automobiles and other vehicles have been made of soft polyurethane foam moldings to provide comfortable cushioning, but in recent years, styrofoam has been used as a raised lower layer to reduce weight. There is a movement to replace it with bead foam m such as (Fig. 14 A). However, in the bead foam m, molding shrinkage occurs during foam molding, resulting in variations in dimensional accuracy.
The cushion pad P is formed by molding a soft polyurethane foam molded product U upside down from the state installed in the vehicle. Since the bead foam m is insert-molded, it is set in the upper mold T using the overhang m1 that protrudes from the back side of the bead foam m. However, if the size is smaller than the specified size, the overhang m1 The overhanging portion elevation m18 separates from the upper mold recess T1 and falls off (FIG. 14B). On the other hand, if the overhanging portion m1 is large, a sticking point m19 is created, making it difficult to set the bead foam m on the upper mold T (FIG. 14C).
For this reason, several inventions have been proposed to prevent the device from falling off or being difficult to attach (for example, Patent Document 1).

JP 2018-130398 Publication

However, in Patent Document 1, the upper mold protrudes from the wall surface of a concave portion sandwiching a convex portion that is a protruding portion of a bead foam (in the present invention, a first foam molded body) so as to interfere with the convex portion. It has a configuration with a metal protrusion. Therefore, if the degree of interference is even slightly large, it will not function, requiring tuning of the mold and adjusting the dimensions of the hard protrusions. Furthermore, even if the bead foam could be set in the upper mold, there was a problem in that the side surface of the bead foam would be scraped by the protrusions.

The present invention solves the above problems, does not require adjustment on the mold side, and eliminates the appearance defects caused by scraping the first foam molded product. It is an object of the present invention to provide a cushion pad for a vehicle that allows interference, facilitates setting, and improves holding power to an upper mold, and a method for manufacturing the same.

In order to achieve the above object, the gist of the invention as set forth in claim 1 is that a seat layer having a contact surface portion on the side that a seated occupant contacts is laminated on a first foamed molded product serving as a lower layer. In a cushion pad for a vehicle in which a two-foam molded product is foam-molded, the first foam molded product has a lower density and greater hardness than the second foam molded product, and a part of the back side of the first foam molded product has a cushion pad. When installed in a vehicle, the raised part has a substantially vertical side wall surface, and a plurality of projecting bulges are formed on the substantially vertical side wall surface of the raised part. A cushion pad for a vehicle is characterized by: A second aspect of the present invention provides a cushion pad for a vehicle according to the first aspect, wherein a plurality of the bulges in the form of vertical stripes are provided in a circumferential direction of the side wall surface. A cushion pad for a vehicle according to a third aspect of the present invention is characterized in that the bulge is formed so as to face downward and have a smaller cross-sectional shape. The cushion pad for a vehicle according to the fourth aspect of the present invention is characterized in that the raised portions are formed in a pair separated in the vehicle width direction, both of the raised portions are disposed on both outer sides in the vehicle width direction, and The bulge is formed to be exposed on opposing side wall surfaces of the parts. The cushion pad for a vehicle according to claim 5 is characterized in that according to any of claims 1 to 4, the raised portion is set at a height such that the raised portion protrudes below the floor surface of the vehicle body when installed in a vehicle. . The invention of claim 6 provides a cushion pad for a vehicle according to claims 1 to 5, in which a depressed area is provided inside the first foam molded body, leaving the outer periphery of the back surface of the first foam molded body, and a depressed bottom of the depressed area is formed. A part of the back surface of the first foamed molded article is raised to form the raised portion.
The gist of the invention according to claim 7 is to foam mold a second foam molded product in which a seat layer having a contact surface portion on the side that a seated occupant contacts is laminated on a first foam molded product to be a lower layer. In the method for manufacturing a cushion pad for a vehicle, the first foamed molded product has a lower density and greater hardness than the second foamed molded product, and a portion of the back surface of the cushion pad is approximately A raised portion having a vertical side wall surface is formed, and a plurality of protrusions are formed on the substantially perpendicular side wall surface of the raised portion, and a plurality of protrusions are formed on the raised portion on the upper mold cavity surface. Form a corresponding recessed hole, turn the back side of the first foamed molded product upward, fit the protrusion into the recessed hole while compressing and deforming the bulge, and place the first foamed molded product in the upper mold. A method for manufacturing a cushion pad for a vehicle, characterized in that the foaming material for the second foam molded article is injected onto the lower mold cavity surface, the mold is closed, and the second foam molded article is then foam-molded. It is in. An eighth aspect of the present invention provides a method for manufacturing a vehicle cushion pad according to the seventh aspect, characterized in that a plurality of the bulges in the form of vertical stripes are formed on the side wall surface. A manufacturing method for a vehicle cushion pad according to a ninth aspect of the present invention is characterized in that, in the seventh or eighth aspect, the cross-sectional shape of the bulge is made smaller downwardly. A tenth aspect of the invention is a method for manufacturing a vehicle cushion pad according to any one of claims 7 to 9, including forming a pair of raised portions spaced apart in the vehicle width direction, and arranging both of the raised portions toward the outside in the vehicle width direction. It is characterized in that the bulges are formed on opposing side wall surfaces of both raised portions.

In the vehicle cushion pad and the manufacturing method thereof of the present invention, although the bulge provided on the side wall surface of the raised portion interferes with the upper mold, since the first foam molded product has a compressively deformable protruding bulge, By compressing and deforming the bulge, the first foamed molded product can be easily set in the upper mold with increased holding power, and exhibits excellent effects.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an overall perspective view of a cushion pad, which is an embodiment of a vehicle cushion pad and a method for manufacturing the same according to the present invention. FIG. 2 is an explanatory cross-sectional view of the cushion pad of FIG. 1 cut in the vehicle width direction. FIG. 2 is a perspective view of the first foam molded product of FIG. 1 viewed from the back side. FIG. 4 is a perspective view of a first foamed molded article in another embodiment instead of FIG. 3, viewed from the back side. FIG. 3 is an explanatory cross-sectional view of a cushion pad in another embodiment instead of FIG. 2; (A) is a sectional view around the protrusion in FIG. 4, and (B) to (D) are views of other embodiments in place of (A). FIG. 6 is an explanatory cross-sectional view showing how the first foam molded article of FIG. 5 is set in the upper mold. (A) is a partially enlarged view of the first foam molded body set in the upper mold, and (B) is a sectional view taken along the line VIII-VIII of (A). FIG. 9 is an explanatory cross-sectional view of injecting the foaming raw material after FIG. 8 . It is an explanatory sectional view of mold closing. FIG. 3 is an explanatory cross-sectional view of the second foamed molded body formed by foaming. 8 is a diagram showing another aspect in place of FIG. 7. FIG. 12 is a diagram showing another aspect in place of FIG. 11. FIG. (A) is a perspective view of a conventional cushion pad, and (B) and (C) are explanatory cross-sectional views showing a problem when setting the first foam molded product of (A) in an upper mold.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The vehicle cushion pad (hereinafter also simply referred to as "cushion pad") and its manufacturing method according to the present invention will be described in detail below.
1 to 13 show one embodiment of the cushion pad of the present invention and its manufacturing method. FIG. 1 is a perspective view of the cushion pad, FIG. 2 is a sectional view of FIG. 1, and FIG. 3 is a view of the first foam molded product of FIG. 1. 4 and 5 are views of other embodiments in place of FIGS. 3 and 2. In FIG. 6, (A) is a sectional view around the protrusion in FIG. 4, and (B) to (D) are (A). Fig. 7 is a cross-sectional view of the first foam molded product shown in Fig. 5 set in the upper mold, and Fig. 8 is a partially enlarged view of (A) with the first foam molded product set in the upper mold. ) is a cross-sectional view taken along the line VIII-VIII of (a), FIG. 9 is a cross-sectional view of injecting the foaming raw material, FIG. 10 is a cross-sectional view of the mold closing, FIG. 11 is a cross-sectional view of the second foam molded product, and FIG. , FIG. 13 is a diagram showing another aspect in place of FIGS. 7 and 11. In each figure, important parts of the invention are emphasized and parts not directly related to the invention are simplified or omitted to make the drawings easier to understand.

(1) Vehicle Cushion Pad The vehicle cushion pad 1 is a cushion pad that supports the lower body of a seated occupant. Applicable to the cushion pad 1 of the rear seat of a vehicle (Figures 1 to 3). If the cushion pad 1 is covered with a skin to form a seat cushion, it becomes a rear seat with an auxiliary seat portion 3C in the vehicle width direction, using a seat back made by covering a known back pad with a skin. FIG. 2 shows the cushion pad 1 installed in a vehicle, with the left-right direction on the page showing the vehicle width direction, and the top on the page showing the top of the vehicle.
The cushion pad 1 includes a first foam molded body 2 and a second foam molded body 3.

The first foamed molded product 2 is a foamed molded product for raising the layer that occupies the lower layer of the cushion pad 1 (FIG. 3). It has a lower density (specifically, apparent density) and higher hardness than the second foam molded body 3. For example, it is composed of a foamed molded product obtained by a so-called bead foaming method. This block-shaped bead foam is formed by in-mold foaming after pre-foaming raw material beads. The bead foam is preferably foamed polystyrene, foamed polypropylene, foamed polyethylene, or a molded product containing at least one of these. The bead foam, in which the air bubbles are sealed, is mostly gas, is lightweight, and is harder than the second foam molded product 3, and has the hardness and shape retention properties as a raising member for the cushion pad 1.

The first foamed molded body 2 has a protruding portion 24 on a part of its back surface 2b side, which has a side wall surface 241 that is substantially vertical (substantially vertical) when the cushion pad is installed in a vehicle (Fig. 2, Figure 3). In the first foam molded body 2, a plurality of protruding bulges 25 are formed intermittently on a side wall surface 241 formed substantially perpendicularly to the raised portion 24. Each bulge 25 may be a wart-like convex portion, but in manufacturing the cushion pad, in order to compress the tip portion 251 of the bulge 25 and set and hold the protrusion 24 in a recessed hole 92 (described later), insertion into the recessed hole 92 is necessary. It is more preferable to use longitudinal striations extending in the direction.

In this embodiment, a pair of substantially square prism-shaped raised portions 24 are formed spaced apart in the vehicle width direction, and here they are arranged on both sides of the vehicle width direction. A projecting bulge 25 is formed to be exposed on the side wall surface 241 of both raised portions 24. When the cushion pad 1 is installed in a vehicle, the back surface 2b of the first foam molded body 2 is arranged approximately horizontally, and the raised portion 24 with the side wall surface 241 as a substantially vertical surface extends downward (vertically) with respect to the back surface 2b. stand out and stand up. When installed in a vehicle, the raised portion 24 is set to a height h such that it protrudes below the vehicle body floor surface 6.
The raised portion 24 has a rectangular shape when viewed from the rear, and its long sides are aligned in the longitudinal direction of the vehicle. A bulge 25 is formed in the side wall surface 241 of the raised portion 24 in the form of vertical stripes in the vertical direction, and a plurality of protruding bulges 25 protrude at a predetermined pitch in the circumferential direction perpendicular to the height direction of the raised portion 24 on the side wall surface 241. molded. In FIG. 3, the plurality of protruding bulges 25 are arranged in parallel leaving a flat portion of the side wall surface 241, but the protruding bulges 25 may be arranged in a wavy manner without having a flat surface.

The protruding bulge 25 here has a triangular cross-section orthogonal to the insertion direction of the protruding portion 24 into the recessed hole 92, with the tip end being the apex as shown in FIG. The cross-sectional shape of the bulge 25 is preferably tapered toward the tip of the bulge 25 as described above. In addition to a triangle, if the shape protrudes into a semicircle, ellipse, trapezoid, etc., the cushion pad will be manufactured to be described later. The tip portion 251 of 25 has a tapered shape and is a part of the first foam molded body 2 that can be compressed and deformed. The tip portion 251 can be compressed and deformed relatively easily depending on the degree of interference, and the protrusion 24 with the bulge 25 can be easily inserted and set into the recessed hole 92.

Further, the first foamed molded article 2 can be made into another type of product having a two-part structure as shown in FIG. The first foam molded body 2 shown in the figure is only shown with a split pad 2N corresponding to the right half side in FIG. The cushion pad 1 will look like this. A protruding bulge 25 is formed on all four side wall surfaces 24. Reference numeral 20 is a punched hole which prevents the passenger from bottoming out when sitting on the seat.

FIG. 6(A) shows a partially enlarged view of FIG. 4 in which the raised portion 24 with the bulge 25 on the side wall surface 241 is raised from the back surface 2b of the first foamed molded product 2. FIG. 6 is a sectional view of the area around the raised portion 24 on the back surface 2b side of the first foamed molded body 2, and the vertical direction when installed in a vehicle is reversed.
A bulge 25 having the same shape in cross section is formed in the vertical striations over the entire vertical direction of the raised portion 24 that stands perpendicularly to the back surface 2b of the first foam, and the bulge 25 is formed in the cushion pad manufacturing method described later. , interferes with the recessed hole 92 of the upper mold 9 to increase the holding force to the upper mold 9. Reference numeral 929 indicates a chamfer of the recessed hole 92, which facilitates insertion of the protrusion 24 with the bulge 25 into the recessed hole 92.

In order to prevent the protrusion 24 fitted into the concave hole 92 from falling out by interfering with the bulge 25, it is preferable to use the configuration shown in FIG. . The bulge 25 may not be provided on all the side wall surfaces 241 of the raised portion 24, but may be provided on two opposing surfaces. The raised portion 24 set in the recessed hole 92 may be maintained in a state in which it does not fall off during the manufacturing process of the cushion pad, even if the side wall surface 241 is slightly inclined and has an upright surface close to a vertical surface. In addition, while the side wall surface 241 maintains an upright state with respect to the back surface 2b, the cross-sectional area of the top surface 242 side of the raised portion 24 is smaller than that of the proximal end so that the raised portion 24 can be easily fitted into the recessed hole 92. It may also be a raised portion 24 that becomes a vertical side wall surface 241 (FIG. 6B). Even if the bulge 25 is a raised part 24 with a bulge 25 that strongly interferes with the recessed hole 92, when the first foam molded product 2 is set in the upper mold 9, the raised part 24 with the bulged 25 can be inserted into the recessed hole 92. becomes easier. Even if the cross-sectional area of the bulge 25 is added to the area of the top surface 242 of the raised portion, it can be made smaller than the opening of the recessed hole 92.

Further, instead of the bulge 25 having an equal cross-sectional shape in the vertical direction as shown in FIG. 6(A), it may be a bulge 25 whose cross-sectional shape gradually decreases downward as shown in FIG. 6(C). The bulge 25 increases the protrusion height f2 at the base end portion (back surface point) compared to the protrusion height f1 at the top surface point. When the protrusion 24 with the bulge 25 is inserted into the recessed hole 92, the bulge 25 and the inner wall 921 of the recessed hole begin to interfere with each other, and the setting of the first foam molded article 2 into the upper mold 9 proceeds smoothly. , and since the degree of interference gradually increases, the holding force to the upper die 9 can be smoothly increased.
Furthermore, the bulge 25 provided on the side wall surface 241 does not need to be provided over the entire vertical direction, and the bulge 25 is formed from the middle of the side wall surface 241 slightly downward from the top surface 242 toward the back surface 2b as shown in FIG. 6(d). The starting point may start and the bulge 25 may extend into a strip.

Further, the first foamed molded body 2 may have a protrusion 24 in the depressed area 23 as shown in FIG. 5, for example. The first foamed molded product 2 has a recessed region 23 that is one step lower inside the outer peripheral portion 22 of the back surface, and the recessed bottom 235 of the recessed region 23 is the back surface 2b of the first foamed molded product 2. A raised portion 24 is formed by raising a portion of the surface. While the outer shape when viewed from the back is the same as that shown in FIG. 3, the outer peripheral part 22 of the back surface is left over the entire circumference, and a depression area 23 of a large depression like a caldera is provided inside the outer peripheral part 22 of the back surface. Then, a pair of raised portions 24 are raised in an island shape in the depressed areas 23 on both sides in the vehicle width direction. The top surface 242 of the raised part 24 and the back surface of the back outer peripheral part 22 are flush with each other, so that when the cushion pad 1 is installed on the vehicle floor surface 6, it is easy to arrange it horizontally. In addition, in FIG. 5, since the cushion pad is manufactured using the upper mold 9 in which the recessed hole 92 for accommodating the pair of raised parts 24 is formed (details will be described later), the two raised parts 24 in FIG. Thus, the opposite side wall surfaces 241 have no bulge 25. The cross-sectional shape of the bulge 25 is semicircular (FIG. 8B).
Reference symbols 2A, 2B, and 2C indicate a main lower layer, a side lower layer, and an auxiliary seat lower layer.

The second foam molded body 3 is a cushion body formed from a soft polyurethane foam molded body, and has a seat layer 31 having a contact surface portion 311 on the side that the seated occupant comes into contact with. A seat layer 31 is laminated on the first foam molded product 2, which becomes the lower layer for raising the layer, and a second foam molded product 3 is foam-molded. A seated occupant contacts the contact surface portion 311 via a not-shown skin covering the cushion pad 1.

1 and 2, in the second foam molded product 3, the seat layer 31 covers the top surface 2a of the core pad, and the side peripheral layer 32 covers the side surface 2d of the first foam molded product 2. The upper surface of the seat layer 31 of the second foam molded body 3 becomes the designed surface on the contact surface portion 311 side that the seated occupant comes into contact with, and the outer surface of the side peripheral layer 32 becomes the side design surface 3d of the second foam molded body 3. Become. The second foamed molded product 3 covers and integrates the first foamed molded product 2, except for the back surface 2b of the first foamed molded product 2, which also serves as the back surface 1b of the cushion pad, thereby completing the cushion pad 1.
Although not shown, the first foamed molded body 2 is provided with a gas venting hole as disclosed in JP-A No. 2017-206077, which penetrates from the top surface 2a to the back surface 2b, and is further provided with a hole diameter of the through hole on the back surface 2b side. It also has a large depression. In the foam molding of the second foam molded body 3, which will be described later, the second foam molded body 3 fills the through holes and depressions, thereby strengthening the second foam molded body 3 integrally with the first foam body. Reference numeral 3A indicates a main part of the passenger seat, 3B indicates a side part, 3D indicates a slope, 3E indicates a joint portion with a backrest, and 39 indicates a hanging groove.

(2) Manufacturing method of vehicle cushion pad For example, when the first foam molded product 2 is shown in FIG. 5, the cushion pad 1 is manufactured by the following manufacturing method (FIGS. 7 to 11). Using the foam mold 7, the second foam molded product 3, in which the contact surface portion 311 on the side that the passenger comes into contact with is formed of a soft polyurethane foam molded product, is foam-molded, and the first foam molded product of the insert product is formed by the foam molding. 2. Manufactures a vehicle cushion pad that is integrated with 2.

Prior to manufacturing the cushion pad, a first foam molded body 2 and a foam mold 7 are prepared. The first foam molded body 2 is the same as that described in (1) cushion pad, and its explanation will be omitted.
The foaming mold 7 is a split mold as shown in FIG. 9, and a lower mold 8 and an upper mold 9 are connected so as to be openable and closable. When the mold is closed as shown in FIG. 10, the entire body is recessed into a bowl shape, and the lower mold cavity surface 81, which forms the design surface of the contact surface portion 311, is substantially flat as a whole, matching the back surface 2b of the first foamed molded product 2. A cushion pad cavity C is created with the upper mold cavity surface 91. When the first foam molded body 2 is set in the upper mold 9, a recessed hole 92 as shown in the figure is formed in the upper mold cavity surface 91 at a position corresponding to the raised portion 24. Here, a large recessed hole 92 as shown in FIG. 7 is provided, including the depressed bottom 235 and accommodating the pair of raised parts 24. The foaming mold 7 molds the cushion pad 1 shown in FIG. 5 upside down.

The manufacturing method of this cushion pad is as follows: First, using the foaming mold 7 and the first foaming molded body 2, with the back side 2b of the first foaming molded body 2 facing up, the two raised portions 24 are combined into one. The first foamed molded product 2 is fitted into the recessed hole 92 and set in the upper mold 9.
A recessed hole 92 provided at a position corresponding to the raised part 24 on the upper mold cavity surface 91 will fit if only the raised part 24 is present, but due to the presence of the bulge 25, when the raised part 24 is fitted, the bulged hole 92 will fit into the recessed part. It collides with the hole forming part F and interferes with it. The bulge 25 is stuck in the concave hole forming portion F at the periphery of the hole opening of the concave hole 92. However, since the bulge 25 is a part of the first foamed molded product 2 and can be compressed and deformed, the bulge 24 is fitted into the recessed hole 92 while compressing and deforming the bulge 25, and the first foam molded body 2 is inserted into the upper mold 9. The foam molded body 2 can be set. When the protrusion 24 with the bulge 25 is pushed into the recessed hole 92 with a little force, the bulge 25 which becomes the interference part with the recessed hole forming part F is compressed by the recessed hole inner wall 921 and elastically deformed. The protruding portion 24 with the bulge 25 is inserted into the recessed hole 92 with the tip portion 251 interfering with the bulge 25 being crushed.

FIG. 8 shows the area around the recessed hole forming part F on the left side of FIG. 7 in which the protrusion 24 is fitted into the recessed hole 92 and is in a set state. shows the compressed part. The elastic restoring force of the crushed compressed portion 252 presses the rising inner wall 921 of the recessed hole, and this pressure also occurs on the inner wall 921 of the recessed hole forming part F on the right side in FIG. The set first foam molded article 2 is held. A bulge 25 is provided on the side wall surface 241 of the raised portion standing up on the back surface 2b of the first foamed molded body 2. To explain with reference to FIG. Since the first foamed molded article 2 is pressed from the inside horizontally outwardly, the first foamed molded article 2 is effectively held in the upper mold 9. Note that the bulge 25 is not provided on the side wall surface of the raised portion 24 shown in FIG. By providing a bulge 25 here as well and making it a concave hole forming part F that interferes with the bulge 25, the protrusion 24 fitted into the concave hole 92 can also form a bulge 25 on the upper and lower inner walls of the concave hole 92 as shown in FIG. A compressed portion formed by crushing the interfering tip portion 251 acts on the upper and lower inner walls 921 and is firmly held by the upper mold 9.

Thereafter, the foaming raw material g for the second foam molded body 3 is injected onto the lower mold cavity surface 81 using the injection nozzle NL or the like.
Next, the upper mold 9 is operated to close the mold (FIG. 10). By closing the upper mold 9 and the lower mold 8, a cushion pad cavity C in which the first foam molded product 2 is inserted and set is formed. In this embodiment, the mold was closed after the foaming raw material g was injected, but the foaming raw material g could also be injected after the mold was closed.

After closing the mold, the process moves to foam molding of the second foam molded body 3. A second foamed molded product 3 having a contact surface portion 311 on the design side and whose inner surface 3b on the opposite side is brought into contact with the top surface 2a of the first foamed molded product 2 to form a seat layer 31 is foam-molded. do. The closed state of the mold shown in FIG. 10 is maintained for a predetermined period of time, and the second foam molded body 3 of the flexible polyurethane foam molded body is foam-molded. A second foam molded product 3 is foam-molded, in which a contact surface portion 311 is formed on the lower mold cavity surface 81, and the inner surface 3b on the opposite side to the contact surface portion 311 is brought into contact with the top surface 2a of the first foam molded product 2. do.
When the foam molding of the second foam molded product 3 is completed and the mold is removed, a desired cushion pad 1 that has achieved weight reduction due to the incorporation of the first foam molded product 2 is obtained (FIG. 5).

12 and 13 show another method of manufacturing a cushion pad using the split pad 2N of FIG. 4 as the first foam molded body 2.
The first foamed molded body 2 shown in FIG. 3 is divided into two parts, and divided pads 2M and 2N are further provided with punch holes 20. A raised portion 24 is provided on each of the divided pads 2M and 2N, and a bulge 25 is formed on the side wall surface 241 of both raised portions 24. All four side wall surfaces 241 have vertically striated bulges 25 as shown in FIG. In the foaming mold 7, an upper mold 9 and a lower mold 8 are closed to form a cavity C that is substantially the same as that of the cushion pad 1 shown in FIG. Recessed holes 92 are provided in the upper mold cavity surface 91 corresponding to the two raised parts 24, and the recessed holes 92 interfere with the bulges 25 while allowing the raised parts 24 to be accommodated. When the split pads 2M and 2N are set on the upper mold 9, the bulge 25 collides with the concave hole forming portion F on the periphery of the concave hole 92. However, the elastically deformable bulge 25 crushes and compresses the interfering tip portion 251, and the protrusion 24 with the bulge 25 can be accommodated in the recessed hole 92.
In the right side split pad 2N in FIG. 12, the elastic restoring force due to the crushing and compression of the original tip portion 251 shown by the chain line acts approximately horizontally outward from all the side wall surfaces 241 on the four sides of the raised portion 24, Since the inner wall 921 of the recessed hole is pressed, the divided pad 2N is securely set and held on the upper die 9. Further, when the raised portion 24 with the bulge 25 is inserted into the recessed hole 92, the divided pad 2N is positioned and set on the upper mold 9 autonomously since the raised portion 24 is approximately rectangular in plan view. Similar to the right side split pad 2N, after the left side split pad 2M in FIG. 12 is set in the upper mold 9, the foaming raw material g for the second foamed molded body 3 is injected onto the lower mold cavity surface 81. Thereafter, the mold is closed, and the second foamed molded body 3 is foam-molded to obtain a desired vehicle cushion pad 1 as shown in FIG. 13.
Reference numeral S indicates a void, reference numeral 29 indicates a locking groove in the skin, and reference numerals 89 and 99 indicate mold matching surfaces on the lower mold side and the upper mold side.

(3) Effect As in the vehicle cushion pad and manufacturing method thereof configured as described above, a portion of the back surface 2b side of the first foam molded body 2 has a side wall surface that becomes approximately vertical when the cushion pad is installed in a vehicle. When the first foam molded product 2 is used as an insert product and a protrusion 24 is formed and a projecting bulge 25 is formed on the side wall surface 241 that is substantially perpendicular to the protrusion 24, the first foam molded product 2 can be used as an insert product. Can be easily set in mold 9. The cushion pad 1 can be made by foam-molding the second foam molded body 3.
A recessed hole 92 is formed in the upper mold cavity surface 91 corresponding to the raised part 24, and when the raised part 24 with the bulge 25 is inserted into the recessed hole 92, although the raised part 24 fits into the recessed hole 92, the bulge 25 is inserted into the recessed hole. It is set so that it collides and interferes around the hole opening of 92. However, since the bulge 25 can be compressed and deformed as part of the first foam molding, the tip end portion 251 of the bulge 25 is crushed, compressed and deformed, and the protrusion 24 with the bulge 25 is smoothly fitted into the recessed hole 92. be able to. Then, a repulsive force acts on the compressed portion 252 where the bulge 25 is crushed and deformed, and this repulsive force presses the inner wall 921 of the recessed hole outward from the compressed portion on the side wall surface 241 of the raised portion 24. The first foam molded body 2 is held in the mold 9.
In Patent Document 1, a protrusion is provided on the upper mold 9 to prevent the first foam molded product 2 from falling off, but the protrusion is made of a hard metal material of the mold and is difficult to handle against the first foam molded product 2 which causes mold shrinkage. It lacks flexibility in deformation. If the degree of interference is even slightly large, it will be necessary to adjust the dimensions of the mold. On the other hand, although the bulge 25 of the present invention is harder than the second foamed molded body 3, it is formed of a bead foam such as foamed polypropylene, and is a protruding bulge 25, so it is too large. Even in this case, the raised portion 24 with the bulge 25 can be easily inserted into the recessed hole 92 by increasing the amount of crushing and deforming it. The first foamed molded body 2 can be easily set in the upper mold 9. Furthermore, even if the raised portion 24 with the bulge 25 is inserted into the recessed hole 92 by force, the first foamed molded product 2 obtained by the bead foaming method or the like will be compressed and deformed. There is no problem of Patent Document 1, such as being scraped at the edges.

When the bulge 25 in the form of vertical stripes is provided, the tip end portion 251 of the bulge 25 is crushed and compressed over the entire height of the side wall surface 241 to form a ridge with the bulge 25 in the recessed hole 92. Since the portion 24 can be fitted, the area of the crushed compressed portion 252 increases, thereby increasing the reaction force and improving the holding force of the first foam molded body 2 to the upper die 9. If the first foamed molded product 2 has the bulges 25 of vertical striations, no undercut can be formed, so that molding becomes easy. If a plurality of bulges 25 are provided in the circumferential direction of the side wall surface 241, the number of compressed portions 252 to be crushed increases to a plurality, so that the holding force of the first foam molded body 2 to the upper mold 9 is equal to the plurality of bulges 25 in the case of one bulge 25. It increases twice.
When the bulge 25 is formed so as to face downward and have a smaller cross-sectional shape, the protrusion 24 with the bulge 25 can be easily inserted into the recessed hole 92. Then, the bulge 25 is caused to interfere with the inner wall 921 of the recessed hole from the middle of insertion, and the degree of interference is gradually increased, so that the holding force to the upper mold 9 can be smoothly increased.

As shown in FIG. 2, a pair of raised portions 24 are formed apart from each other in the vehicle width direction, and both are disposed toward both outer sides in the vehicle width direction. When the bulge 25 is exposed and formed on the side wall surface 241, it becomes easy to set the frame 5 that guides and holds the cushion pad 1. Naturally, the frame 5 also has dimensional errors, but this error is absorbed by the bulge 25 (FIG. 2). Compressive deformation of the tip portion of the protruding bulge 25 protruding from the side wall surface 241 of the raised portion 24 allows fine adjustment with respect to the frame 5 side. The allowable range of usable frames 5 is expanded, contributing to improved yield.
When installed in a vehicle, if the raised portion 24 is set to a height that projects below the vehicle body floor surface 6, the raised portion 24 and the bulge 25 are accommodated in the vehicle body floor surface 6 opposite to the raised portion 24. By providing the recess 61 or the punched hole, the cushion pad 1 can be easily attached and fixed to the vehicle body (FIG. 2). The cushion pad can prevent the vehicle from rolling.

Leaving the outer circumferential portion 22 of the back surface of the first foam molded product 2, a depressed region 23 that is one step lower is provided inside thereof, and the depressed bottom 235 of the depressed region 23 is used as a part of the back surface 2b of the first foam molded product 2. When the raised part 24 is formed, there are almost no restrictions on where the raised part 24 is provided on the back surface 2b side of the first foamed molded body 2, and the degree of freedom in design increases.
As described above, the present vehicle cushion pad and its manufacturing method exhibit the various excellent effects described above.

Note that the present invention is not limited to what is shown in the embodiments described above, and can be variously modified within the scope of the present invention depending on the purpose and use. The shape, size, number, material, etc. of the cushion pad 1, first foam molded body 2, protrusion 24, bulge 25, second foam molded body 3, foam mold 7, etc. can be appropriately selected according to the purpose. When a pair of raised parts 24 are formed apart in the vehicle width direction, and both are arranged toward the outside, the bulges 25 do not need to be provided on all the side wall surfaces 241 of both raised parts 24, and as shown in FIG. It is sufficient that the bulges 25 are exposed and formed at least on the opposing side wall surfaces 241 of both raised portions 24 .

1 Cushion pad 2 First foam molded product 24 Protruding portion 241 Side wall surface 25 Swelling 3 Second foam molded product 31 Seat layer 311 Contact surface portion 81 Lower mold cavity surface 91 Upper mold cavity surface 92 Recessed hole 95 Engagement portion F Recessed hole Forming part g Foaming raw material

Claims (10)

A cushion pad for a vehicle in which a second foam molded product is foam-molded, in which a second foam molded product is laminated on a first foam molded product serving as a lower layer, and a seat layer having a contact surface portion on the side that a seated occupant contacts,
The first foamed molded product has a lower density and greater hardness than the second foamed molded product, and has a side wall surface on a part of the back surface that becomes substantially vertical when the cushion pad is installed in a vehicle . 1. A cushion pad for a vehicle, comprising a raised part raised from a back surface , and a plurality of projecting bulges formed on the substantially perpendicular side wall surface of the raised part. 2. The cushion pad for a vehicle according to claim 1, wherein a plurality of said bulges in the form of vertical stripes are provided in a circumferential direction of said side wall surface. 3. The vehicle cushion pad according to claim 1, wherein the bulge is formed so that its cross-sectional shape decreases downward. Claim 1: A pair of said protrusions are formed apart in the vehicle width direction, both of which are disposed outwardly in the vehicle width direction, and said bulges are exposed and formed on opposing side wall surfaces of both protrusions. 4. The vehicle cushion pad according to any one of items 3 to 3. The cushion pad for a vehicle according to any one of claims 1 to 4, wherein the raised portion is set at a height such that it projects below the floor surface of the vehicle body when installed in a vehicle. Leaving the outer periphery of the back surface of the first foamed molded product, a depressed region that is one step lower is provided inside thereof, and the depressed bottom of the depressed region is used as the back surface of the first foamed molded product, and a part of it rises to form the raised portion. The vehicle cushion pad according to any one of claims 1 to 5, wherein the cushion pad is formed with:. In a method for manufacturing a vehicle cushion pad, a method for manufacturing a vehicle cushion pad includes foam-molding a second foam molded product in which a seat layer having a contact surface portion on the side that a seated occupant contacts is laminated on a first foam molded product serving as a lower layer,
The first foamed molded product has a lower density and greater hardness than the second foamed molded product, and has a side wall surface that is substantially vertical on a part of the back surface when the cushion pad is installed in a vehicle. A raised part is formed from the mold, and a plurality of protruding bulges are formed on the substantially perpendicular side wall surface of the raised part, and a recessed hole corresponding to the raised part is formed in the upper mold cavity surface. ,
With the back side of the first foamed molded product facing upward, while compressing and deforming the bulge, the protrusion is inserted into the recessed hole, and the first foamed molded product is set in an upper mold;
Next, the foaming raw material for the second foamed molded body is injected onto the lower mold cavity surface, and the mold is closed.
A method for manufacturing a cushion pad for a vehicle, characterized in that the second foam molded article is then foam-molded. 8. The method of manufacturing a cushion pad for a vehicle according to claim 7, wherein a plurality of said bulges in the form of vertical stripes are formed on said side wall surface. The method for manufacturing a vehicle cushion pad according to claim 7 or 8, wherein the cross-sectional shape of the bulge is made smaller downward. Any one of claims 7 to 9, wherein a pair of the raised portions are formed apart in the vehicle width direction, and both are disposed toward both outer sides in the vehicle width direction, and the bulge is formed on opposing side wall surfaces of both raised portions. 2. The method for manufacturing a vehicle cushion pad according to item 1.

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