JP2011000172A - Seat pad support member and method for designing support material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a seat pad support member capable of being used for producing a prototype of a support material and able to shorten a starting time of a seat pad foaming/molding operation thereby and a method for designing the support material using the seat pad support member.SOLUTION: The seat pad support member 10 is used for hardness measurement of the seat pad 5. An upper face 11 of the support member 10 has a form capable of approximately wholly coming in close contact with the lower face of the pad 5. In the case of designing the support material 6, while a sheet material 12 is brought into contact with the upper face 11 of the member 10, the sheet material 12 is cut and sewn to be a form coming in close contact with the upper face 11 to produce the prototype of the support material 6. Thereafter the prototype is unsewed to be developed flat on a plane. A design drawing (developed drawing) of the support material 12 is produced from the developed form.

Description

  In the present invention, a seat pad support member is disposed below the hardness measurement target portion of the seat pad, a pressure plate is pressed against the upper surface of the hardness measurement target portion, and the hardness measurement target portion is placed on the sheet pad support member and the pressure plate. The present invention relates to a seat pad support member used in a hardness measurement method for measuring the hardness of a seat pad by compressing between and. Moreover, this invention relates to the method of designing the support material of the shape which follows the lower surface of a seat pad using this seat pad support member.

I. A method for measuring the hardness of a seat pad attached to a vehicle seat is defined in JASO (Japan Automobile Manufacturers Association Standard) B408-89. When measuring the hardness according to this rule, place a test piece on a horizontal table of a testing machine, and place a disk-shaped pressure plate attached to the testing machine on the center of the upper surface of the test piece. Next, an initial load of 5 N is applied to the test piece with this pressure plate, and the thickness is measured, which is defined as the initial thickness. Next, as a precompression, the pressure plate is compressed to a distance of 75% of the initial thickness at a speed of 50 mm / min, and then the load is removed immediately. Then, after leaving it for 3 to 5 minutes, it compresses to the distance of 25% of initial thickness, and after making it stand still for 20 seconds, a load is measured. This is 25% hardness.

  As this test piece, a molded product foam-molded into a block shape of a predetermined size with the same material as the seat pad, a core part cut out of a central core portion of the molded body into a rectangular column shape of a predetermined size, or a seat pad molded product Itself is used.

  Place the seat pad molded product on the horizontal platform of the testing machine, and measure the hardness by compressing the lower part of the seat pad molded product (the part on which the occupant's buttocks rest when the vehicle occupant is seated) from above with a pressure plate It has also been done. In this case, a seat pad support member is installed on the lower side of the seat pad molded product so as to be in close contact with the lower surface of the bottom of the seat pad molded product, and the seat pad molded between the seat pad support member and the pressure plate. Compress the product. The hardness measurement is performed in the same manner for the seat pad constituting the seat back portion.

II. The seat pad is manufactured by injecting a urethane compound stock solution obtained by mixing a polyol component compound solution and an isocyanate component into a mold and foam molding.

  FIG. 4 is a flowchart showing a general manufacturing method of a conventional mold for forming a seat pad. First, a prototype 1 having the same shape as the seat pad is produced (FIG. 4 (a)). Considering that the metal material poured into the molds 3a and 3b in the mold casting stage, which will be described later, is thermally shrunk during curing, the outer dimensions of the original mold 1 are slightly larger than the design dimensions of the mold (for example, 1 to 1). (About 2%). This prototype 1 is produced by cutting a resin material such as hard urethane, for example.

  Next, this prototype 1 is put into a mold (not shown), and this is filled with gypsum, synthetic resin, etc., and a modeling mold (inverted mold) 2 is produced (FIG. 4 (b)). The modeling mold 2 can be divided into a plurality of parts in consideration of demolding. In FIG. 4 (b), the modeling mold 2 is divided into two parts, an upper mold 2a and a lower mold 2b. However, it may be divided into three or more if necessary, and a core is provided. Sometimes.

  Next, an upper mold 3a and a lower mold 3b are produced from the upper mold 2a and the lower mold 2b of the modeling mold 2 with mold sand, respectively (FIG. 4 (c)). Thereafter, molten metal such as an aluminum alloy is poured into the molds 3a and 3b, and the upper mold 4a and the lower mold 4b constituting the seat pad molding mold 4 are cast (FIG. 4 (d)).

  In order to simplify the mold manufacturing process, Japanese Patent Application Laid-Open No. 2003-181596 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2002-240059 (Patent Document 2) cut block-shaped synthetic resin materials and the like with an automatic processing machine. Manufacturing a mold is described. Japanese Patent Laid-Open No. 2002-321226 (Patent Document 3) obtains the cross-sectional shape of each layer when the die is divided into a plurality of layers from the CAD data of the die, and is cut into a shape that matches the cross-sectional shape of each layer. It describes that a metal mold | die is manufactured by laminating | stacking a some base material and forming a metal layer in the laminated | stacked base material surface after that. Japanese Patent Application Laid-Open No. 2002-36246 (Patent Document 4) describes that a mold is manufactured by direct carving of aluminum.

  In order to reinforce the seat pad, a support material may be provided along the lower surface of the seat pad. FIG. 5 is a schematic longitudinal sectional view of the seat pad 5 with the support material 6. Generally, the support material 6 is obtained by sewing a base fabric (raw fabric) made of a fiber material so as to have a three-dimensional shape along the lower surface of the seat pad 5. The support material 6 is integrally formed with the seat pad 5. That is, in performing foam molding of the seat pad 5, as shown in FIG. 6, the support material 6 is disposed along the cavity surface of the upper mold 4a for molding the lower surface of the seat pad 5, and the inside of the lower mold 4b. After the urethane raw material 7 is filled in, the mold is clamped, heated and foamed. After the foamed urethane material is cured, the mold is opened and removed. Thereby, the molded product of the seat pad 5 with the support material 6 shown in FIG. 5 is obtained.

  In general, when designing the support material 6, the base material is applied to the cavity surface of the upper mold 4a, and the support material 6 is cut and stitched so that the base fabric is in close contact with the cavity surface. Make it. After that, the prototype is unzipped and flattened on a flat surface, and a design drawing (development drawing) of the support material 6 is created based on the developed shape.

  Japanese Patent Laid-Open No. 2001-353732 (Patent Document 5) describes a method for creating a design drawing of a support material based on CAD data of a sheet pad molding die or CAD data of a seat pad.

JP2003-181596 JP2002-240059 JP2002-321226 JP 2002-36246 A JP 2001-353732 A

  As described above, when a support material prototype is produced using a seat pad molding die and the support material is designed based on the prototype, the support material design is performed unless the seat pad molding die is completed. Can not do. Therefore, even if the mold is completed, the seat pad foam molding operation cannot be started immediately, so the start timing of the seat pad foam molding operation is delayed.

  In the above Patent Documents 1 to 4, the manufacturing process of the mold is simplified, so that the period required for manufacturing the mold is shortened. However, even in Patent Documents 1 to 4, since it is necessary to produce a prototype of the support material using the completed mold, it is not possible to immediately start the foam molding operation of the seat pad after the mold is completed.

  In addition, it is also conceivable to produce a prototype of the support material using an original mold or a modeling mold that is manufactured in the manufacturing process of the seat pad molding die. However, as described above, these prototypes and modeling molds are slightly larger than the design dimensions of the seat pad in consideration of the fact that the metal material is thermally shrunk during curing in the mold casting stage. The prototype of the support material produced using the original mold or the modeling mold is larger than the seat pad molded product.

  In the above-mentioned Patent Document 5, since the design drawing of the support material is created based on the CAD data of the seat pad molding die or the CAD data of the seat pad, the support is provided even if the seat pad molding die is not completed. Prototypes of materials can be made. However, it is difficult to accurately predict subtle deformations of the base fabric caused by stitching etc. from CAD data, and it is necessary to check the distortion and error along the cavity surface by actually prototyping. 5, the foam pad molding operation cannot be started immediately after the mold is completed.

  An object of the present invention is to provide a seat pad support member that can be used for producing a prototype of a support material, and thereby can accelerate the start timing of foam molding work of the seat pad. . It is another object of the present invention to provide a support material design method using the seat pad support member.

  In the seat pad support member of the present invention (invention 1), the seat pad support member is disposed below the hardness measurement target portion of the seat pad, a pressure plate is pressed against the upper surface of the hardness measurement target portion, and the hardness measurement is performed. A seat pad support member used in a hardness measurement method for measuring the hardness of a seat pad by compressing a target portion between the seat pad support member and a pressure plate, wherein the seat pad support member The first seat pad support surface that supports the lower surface of the hardness measurement target portion, and the lower surface of at least a portion of the portion of the seat pad other than the hardness measurement target portion and the support material provided on the lower surface. And a second seat pad support surface.

  The seat pad support member according to claim 2 is characterized in that, in claim 1, the first seat pad support surface and the second seat pad support surface are continuous.

  According to a third aspect of the present invention, the seat pad support member according to the first aspect is characterized in that the first seat pad support surface and the second seat pad support surface are separated from each other.

  The seat pad support member according to claim 4 is the seat pad support member according to any one of claims 1 to 3, wherein the second seat pad support surface is a portion other than a hardness measurement target portion of the seat pad and is provided on a lower surface with a support material. It is characterized in that it supports substantially the entire lower surface of the portion provided with.

  The seat pad support member according to claim 5 is the seat pad support member according to any one of claims 1 to 4, wherein the seat pad support member is made of synthetic resin, and the synthetic resin includes hard urethane and chemical wood. To do.

  The support material design method according to the present invention (Claim 6) is a support material design method provided along the lower surface of the seat pad, and the seat pad support member according to any one of claims 1 to 5. While the sheet-like material is applied to the first and second sheet pad support surfaces, the sheet-like material is cut and stitched so that the sheet-like material is in close contact with the first and second sheet pad support surfaces. This is characterized in that a prototype is made and a support material is designed based on this prototype.

  The seat pad support member of the present invention (Claim 1) is a first seat pad support surface that is in close contact with the lower surface of the hardness measurement target portion of the seat pad, and a lower surface that is a portion other than the hardness measurement target portion of the seat pad. And a second seat pad support surface that is in close contact with the lower surface of at least a portion of the portion provided with the support material. Therefore, the sheet-like material is cut and stitched so as to be in close contact with the first and second sheet pad support surfaces while applying the sheet-like material to the first and second sheet pad support surfaces. A prototype support material having a shape along the lower surface of the pad can be produced. Therefore, even if the seat pad molding die is not completed, a prototype of the support material is made using this seat pad support member, and the support material design drawing is made based on that to manufacture the support material. As a result, the foam molding operation of the seat pad with the support material can be started immediately after the mold for molding the seat pad is completed.

  In addition, since the prototype of the support material can be produced using the seat pad support member used when measuring the hardness of the seat pad in this way, it is necessary to produce a dedicated mold for producing the prototype of the support material. Therefore, the increase in cost can be suppressed.

  In the present invention, the first seat pad support surface and the second seat pad support surface may be continuous (Claim 2) or may be separated (Claim 3). In addition, the second seat pad support surface may be configured to be in close contact with the entire lower surface of the portion of the seat pad other than the hardness measurement target portion and where the support material is provided on the lower surface. (Claim 4).

  The seat pad support member only needs to have hardness and rigidity that do not substantially deform when a load is applied from the pressure plate to the seat pad when measuring the hardness of the seat pad. Therefore, as the material of the seat pad support member, as described in claim 5, a material that is relatively easy to process, such as hard urethane or chemical wood, can be used.

  According to the support material design method of the present invention (Claim 6), since a prototype of the support material is produced using the seat pad support member of the present invention, the seat pad molding die is not completed. It is possible to create a prototype of the support material and create a design drawing of the support material based on the prototype. Therefore, it is possible to start production of the support material before the seat pad molding die is completed. As a result, immediately after the mold for seat pad molding is completed, foam molding of the seat pad with support material is started. It becomes possible to do.

It is a longitudinal cross-sectional view which shows the hardness measuring method of the seat pad using the seat pad supporting member which concerns on embodiment. It is a longitudinal cross-sectional view which shows the preparation procedure of the prototype of a support material using the seat pad support member of FIG. FIG. 3 is a schematic development view in which a prototype of the support material of FIG. 2 is developed on a plane. It is a flowchart which shows the manufacturing method of the general mold for sheet pad shaping | molding. It is a schematic longitudinal cross-sectional view of a seat pad with a support material. It is a schematic longitudinal cross-sectional view of the metal mold | die for seat pad shaping | molding which shows the manufacture procedure of the seat pad with a support material of FIG.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a longitudinal sectional view showing a hardness measurement method for a seat pad 5 using a seat pad support member 10 according to an embodiment. FIG. 2 is a longitudinal sectional view showing a procedure for producing a prototype of the support material 6 using the seat pad support member 10. FIG. 3 is a schematic development view in which a prototype of the support material 6 is developed on a plane. In this embodiment, the support material 6 covers substantially the entire lower surface of the seat pad 5.

  As shown in FIG. 1, when the hardness of the seat pad 5 is measured, the seat pad support member 10 is installed on the horizontal table T, the seat pad 5 is placed on the seat pad support member 10, and the seat A disc-shaped pressure plate P is pressed from above on the bottom part H as a hardness measurement target portion of the pad 5, and the bottom part H is compressed between the seat pad support member 10 and the pressure plate P to thereby increase the hardness. taking measurement.

  In this embodiment, the seat pad support member 10 is sized to mount substantially the entire seat pad 5, and the upper surface 11 has a shape capable of supporting substantially the entire lower surface of the seat pad 5. Of this upper surface 11, the region that is in close contact with the lower surface of the bottom portion H of the seat pad 5 is the first seat pad support surface, and the other region is the second seat pad support surface. The second seat pad support surfaces are formed continuously. The configuration of the upper surface 11 of the seat pad support member 10 is not limited to this.

  The seat pad support member 10 is produced, for example, by cutting a synthetic resin material or the like with an automatic processing machine so as to form an inverted mold on the lower surface of the seat pad 5 based on CAD data for design of the seat pad 5. . The seat pad support member 10 only needs to have hardness and rigidity that do not substantially deform when a load is applied from the pressure plate P to the seat pad 5 when the hardness of the seat pad 5 is measured. Therefore, as the material of the seat pad support member 10, a material that is relatively easy to process, such as hard urethane or chemical wood, can be used. However, the manufacturing method and material of the seat pad support member 10 are not limited to this.

  Since the upper surface 11 of the seat pad support member 10 has a shape capable of supporting substantially the entire lower surface of the seat pad 5, the support material 6 can be designed using the seat pad support member 10. That is, in designing the support material 6, as shown in FIGS. 2 (a) and 2 (b), the sheet material 12 is applied to the upper surface 11 of the seat pad support member 10 while the sheet material 12 is applied. A prototype of the support material 6 is produced by cutting and stitching so as to be in close contact with the upper surface 11. Thereafter, as shown in FIG. 3, the prototype is unzipped and flattened on a flat surface, and a design drawing (development drawing) of the support material 6 is created based on the developed shape. The sheet material 12 may be the same material as the support material 6 or may be different.

  The seat pad support member 10 can be manufactured in a separate process from the seat pad molding die 4 and more easily than the die 4. Specifically, for example, the prototype 1 produced in the manufacturing process of the mold 4 is a model of the entire seat pad 5, but the seat pad support member 10 is modeled only on the lower surface side of the seat pad 5. Therefore, the seat pad support member 10 can be produced with a work amount that is about half of the work amount required to produce the prototype 1. Therefore, for example, if the manufacturing operation of the seat pad support member 10 is started at the same time as the manufacturing operation of the mold 4 is started, the seat pad support member 10 can be completed very early than the mold 4. it can. Thus, before the mold 4 is completed, a prototype of the support material 6 is produced using the seat pad support member 10, and a design drawing of the support material 6 is created on the basis thereof to manufacture the support material 6. Can start. As a result, after the mold 4 is completed, the foam molding operation of the seat pad 5 with the support material 6 can be started immediately.

  In addition, the prototype of the support material 6 manufactured using the seat pad support member 10 in this way is cut and stitched while the sheet material 12 is actually applied to the surface along the lower surface of the seat pad 5. Therefore, since the distortion and error with respect to the shape of the lower surface of the seat pad 5 are smaller than the prototype produced from the CAD data of the seat pad 5 as in Patent Document 5, the support material is based on this prototype. 6 designs and manufactures can be performed.

  As a precaution, after the mold 4 is completed, the prototype may be mounted on the cavity surface of the upper mold 4a, and distortion or error of the prototype may be confirmed. In this case, even if distortions or errors occur in the prototype, the distortions and errors are small compared to the prototype produced from the CAD data of the seat pad 5, and can be easily corrected. Therefore, the start time of the foam molding operation of the seat pad 5 is not excessively delayed.

  The above embodiment shows an example of the present invention, and the present invention is not limited to the above embodiment.

  For example, in the above embodiment, the support material 6 is provided on substantially the entire lower surface of the seat pad 5, but the support material 6 may be provided only on a part of the lower surface of the seat pad 5. In this case, the upper surface 11 of the seat pad support member 10 supports only the bottom portion H as a hardness measurement target portion of the seat pad 5 and a portion other than the bottom portion H and the portion provided with the support material 6. Any shape other than the lower bottom H and a shape that does not adhere to the lower surface of the portion where the support material 6 is not provided may be used.

  In the present invention, a portion of the seat pad support member 10 that supports the bottom portion H of the seat pad 5 and a portion that supports a portion other than the bottom portion H of the seat pad 5 may be provided separately. .

  In the above embodiment, the sheet-like material 12 in which the prototype of the support material 6 is flattened is continuous as a whole, but may be divided into a plurality of cut pieces.

  In the above embodiment, the seat pad 5 constitutes a seat portion of the seat (a portion on which the seated person's buttocks rest), but the present invention constitutes a seat pad other than this, for example, a seat back portion. The present invention is also applicable to a seat pad support member and a support material design method.

DESCRIPTION OF SYMBOLS 1 Prototype 2 Modeling mold 3a Upper mold 3b Lower mold 4 Sheet pad mold 5 Sheet pad 6 Support material 10 Sheet pad support member 11 Upper surface of sheet pad support member 12 Sheet material

Claims (6)

A seat pad support member is disposed below the hardness measurement target portion of the seat pad, a pressure plate is pressed against the upper surface of the hardness measurement target portion, and the hardness measurement target portion is disposed between the seat pad support member and the pressure plate. A seat pad support member used in a hardness measurement method for measuring the hardness of a seat pad by compressing with,
The seat pad support member includes a first seat pad support surface that supports the lower surface of the hardness measurement target portion of the seat pad,
A seat having a second seat pad support surface for supporting at least a part of a lower surface of a portion of the seat pad other than the hardness measurement target portion and having a support material provided on the lower surface. Pad support member.   The seat pad support member according to claim 1, wherein the first seat pad support surface and the second seat pad support surface are continuous.   2. The seat pad support member according to claim 1, wherein the first seat pad support surface and the second seat pad support surface are separated from each other.   4. The second seat pad support surface according to claim 1, wherein the second seat pad support surface is a portion other than the hardness measurement target portion of the seat pad, and substantially the entire lower surface of the portion where the support material is provided on the lower surface. A seat pad support member that supports the seat pad.   5. The seat pad support member according to claim 1, wherein the seat pad support member is made of a synthetic resin, and the synthetic resin includes hard urethane and chemical wood. A support material design method provided along the lower surface of the seat pad,
The sheet-like material is applied to the first and second sheet pads while the sheet-like material is applied to the first and second sheet-pad supporting surfaces of the seat pad supporting member according to any one of claims 1 to 5. A support material design method, wherein a support material prototype is produced by cutting and stitching so as to form a shape closely contacting a support surface, and the support material is designed based on the prototype.

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