JP6356044B2 - Seat pad with flow distribution main member and method for manufacturing the same - Google Patents

Description

  The present invention relates to a seat pad with a flow distribution main member constituting a vehicle seat and a method for manufacturing the same.

  There are seat cushions and seat backs that constitute a seat portion and a backrest of a seat seat mounted on a vehicle such as an automobile. The seat cushion and the seat pad of the seat back are the parts that come into contact with each other through the epidermis when the occupant sits down, and the occupant sweats in the hot season, but may feel cold in the winter season. For this reason, the present applicant has proposed an invention in which a seat pad is integrally foamed by inserting a duct for air distribution in Japanese Patent Laid-Open No. 2012-368, Japanese Patent Laid-Open No. 2012-81161, etc. In addition to ensuring quality, there are also expectations for lower costs. Under these circumstances, an improved invention that does not use an air duct is proposed (for example, Patent Document 1).

JP 2013-10000000 A

  However, Patent Document 1 describes in paragraph 0016, “The flow path portion 20 is a flow path for guiding the air blown by the blower 10 to the seating side, and has a groove portion 22 and a plurality of hole portions 24 (FIGS. The groove portion 22 is a substantially H-shaped (front view) recessed portion and can be formed on the back surface of the cushion material 6P (in the storage portion 6X). There is a concern that the flow path portion 20 made of the material may be crushed. Even if the groove portion 22 is only formed by foam molding of the cushion material 6P, and the back surface material 40 is applied to the groove portion 22, if the occupant sits on the vehicle seat, the flow passage portion is deformed and the required flow rate cannot be secured. There is concern.

  The present invention solves the above-described problem, and can reliably distribute air-conditioned air comfortable to the occupant, and can provide a seat pad with a flow distribution main member for quality distribution and cost reduction, and the manufacture thereof. It aims to provide a method.

In order to achieve the above object, the gist of the invention described in claim 1 is that a seat pad made of a foam and a hook-shaped portion formed in a U-shaped cross section along the back surface of the seat pad are open side portions. A flow distribution main member disposed on the back surface side, and a backing material covering the inner surface of the bowl-shaped portion and the back surface of the seat pad, wherein the seat pad is the flow channel main member. And an air blowout port in the flow path main member and a through hole in the backing material. In addition to conducting from the through hole to the air outlet, a plurality of through holes are provided in the saddle-like portion at a portion corresponding to the surface side of the seat pad. The foaming material has passed through the through-holes and has been impregnated and cured in the backing material. In air distribution passage main member containing the seat pad, wherein.
According to a second aspect of the present invention, the seat pad with a flow distribution main channel member according to the first aspect of the present invention has a hole diameter smaller than the hole diameter of the air outlet at the portion of the backing material arranged in the air outlet. The through hole is provided. According to a third aspect of the present invention, there is provided a seat pad including a main channel member for air distribution according to the first or second aspect, wherein the outer ridge projecting outward is formed on the outer surface at the intermediate height of the opposite side wall of the ridge-shaped portion. It is characterized by being formed integrally with the part. A seat pad with a flow distribution main channel member according to a fourth aspect of the present invention is the seat pad according to any one of the first to third aspects, wherein a hole is provided in the opposite side wall of the flange-shaped portion made of synthetic resin, and the hole is disposed in the hole. The backing material is provided with a bulging portion that bulges outward from the inner surface side of both side walls through a hole. A sheet pad with a flow distribution main channel member according to a fifth aspect of the present invention is the sheet pad according to any one of the first to fourth aspects, wherein the opening side portion of the bowl-shaped portion is provided with a sheet-like or plate-like shape via the backing material The flow passage sub member is attached with a lid, and the air distribution flow passage sub member and the flow passage main member form a cylindrical ventilation flow passage.
The gist of the invention described in claim 6 is that, along the back surface of the foam seat pad, the opening side portion of the hook-shaped portion formed in a U-shaped cross section is the back surface side, A flow distribution main member having an air-shaped portion is disposed, and an inner surface of the saddle-shaped portion and a back surface of the seat pad are covered with a cloth backing material, and the sheet pad is covered with the main flow channel member and the backing. A method of manufacturing a seat pad with a flow distribution main member that is integrally foam-molded with a material, comprising a split mold, and a single mold is provided with a recess for an air outlet from which air is ejected from the surface of the seat pad While the raised portion to be formed is provided, the other split mold is provided with a raised portion, and further using a foaming die provided with a protruding portion protruding on the tip surface of the raised portion, Fit the through hole formed in the backing material and the air outlet formed in the bowl-shaped portion in order, The backing material is attached and set to the part, and further, the flow path main member provided with a plurality of spaced apart through holes is attached to the portion of the hook-like part corresponding to the seat pad surface side, and then the mold is closed, Thereafter, the projecting end surface of the convex portion comes into contact with the tip of the raised portion, and a seat pad that conducts from the through hole to the air outlet is integrally foamed with the flow path main member and the backing material, In addition, in the foaming of the seat pad, a foaming raw material passes through the through-hole and is impregnated and cured in the backing material. is there. According to a seventh aspect of the present invention, there is provided a method for manufacturing a seat pad including a flow distribution main member according to the sixth aspect of the present invention, wherein a saddle-like protruding portion is further formed on a side surface of the rising portion, and is attached to the rising portion. In the set flow channel main member made of synthetic resin, a hole is formed in the side wall facing the protruding portion, and the backing material and the flow channel main member are attached to the raised portion, The protruding portion is inserted into the hole, and the backing material is pushed out to the outside of the flow path main member so that the bulging portion is formed.

  The seat pad with a flow distribution main member for air distribution according to the present invention and the method for manufacturing the same ensure reliable air distribution of comfortable air-conditioning air to the seated occupant and maintain the quality. Excellent effects such as low cost.

It is the perspective view which looked at the sheet pad with a channel main member from the back side in one form of the sheet pad with a channel main member concerning the present invention, and its manufacturing method. It is a principal part expanded arrow line view of the II-II line | wire of FIG. FIG. 3 is a diagram illustrating another embodiment instead of FIG. 2. It is a partial section perspective view around an air blower outlet. It is explanatory sectional drawing which sets a backing material and a flow-path main member to an upper mold | type. It is explanatory sectional drawing of the foaming type | mold which has inject | poured the foaming raw material in the mold open state after the backing material and the flow-path main member are set. It is explanatory sectional drawing which shows a mode that the mold was closed after foaming raw material injection | pouring of FIG. FIG. 6 is an enlarged cross-sectional view showing a state in which (a) sets the flow path main member in the upper mold, and (b) is an enlarged cross-sectional view after the setting of (A) is completed. FIG. 8 is an enlarged cross-sectional view around the flow path main member after foam molding after FIG. 7. FIG. 4 is a comparison explanatory diagram when there is no through-hole or through-hole peripheral portion in FIG. 3. In the modification of FIG. 1, it is the perspective view which looked at the sheet pad containing a flow-path main member from the back surface side. It is a fragmentary sectional perspective view around the air blower outlet of FIG.

Hereinafter, the seat pad with a flow distribution main member according to the present invention and the manufacturing method thereof will be described in detail.
A seat pad including a flow distribution main member for air distribution (hereinafter, also simply referred to as “seat pad including a flow channel main member”) and a manufacturing method thereof are applied to a cushion pad constituting a seat portion on which an occupant sits. 1 to 10 show one embodiment of a seat pad with a flow path main member and a method for manufacturing the same according to the present invention. FIG. 1 is a perspective view of the seat pad as viewed from the back side, and FIG. FIG. 3 is an alternative view in place of FIG. 2, FIG. 4 is a partial cross-sectional perspective view around the air outlet, and FIG. 5 is an explanatory cross-sectional view in which a backing material and a flow path main member are set on the upper die, FIG. 6 is an explanatory sectional view of a foaming mold in which a foaming raw material is injected in a mold open state after the backing material and the flow path main member are set, and FIG. 7 is an explanatory view showing a state in which the mold is closed after the foaming raw material is injected in FIG. FIG. 8 is a sectional view showing another embodiment in place of FIG. 5, and is an enlarged sectional view showing a state in which the flow channel main member is set in the upper die. FIG. 9 is a view around the flow channel main member after foam molding after FIG. 7. FIG. 10 is a comparison explanatory view in the case where there is no through hole or through hole peripheral portion in FIG. In order to make the drawings easy to understand, the main parts are drawn with a large emphasis and the drawings are simplified.

(1) Seat pad with flow distribution main member for air distribution The sheet pad with flow distribution main member has a flow passage main member 2, a backing material 6, and foam-molded integrally therewith, and air blowing on the surface side. And a seat pad 1 made of a cushion pad provided with a plurality of outlets 10 (FIG. 1).
In the present invention, the “front side” refers to the side of the seat pad surface that abuts through a sheet-like skin such as fabric when the occupant sits on the seat, and the “back side” refers to the opposite side. . Since the seat pad 1 is foam-molded with the back surface 1b side up, in FIG. 2 to FIG. 9, the lower side of the page is the front side and the upper side of the page is the back side.

  The flow path main member 2 is a synthetic resin member in which the hook-shaped portion 3 formed in a U-shaped cross section along the back surface 1b of the seat pad 1 is disposed with the opening side portion 30 as the back surface side ( Fig. 1 and Fig. 2). The flow path main member 2 includes a bowl-shaped part 3 and an air introduction part 41 that guides air-conditioned air to the bowl-shaped part 3.

  The saddle-like portion 3 has side walls 32 standing up from both side edges of the bottom wall 31, and the front end edges of both side walls 32 are substantially flush with the seat pad back surface 1b, as shown in FIG. 30 is arranged. As shown in FIG. 1, the bowl-shaped portion 3 of the present embodiment is on the seat pad back surface 1 b side, from the air introduction portion 41 located at the center of the main portion 12 near the rear of the vehicle, to the vehicle traveling direction (in the diagonally lower left direction in FIG. 1). After proceeding and reaching a substantially middle point on the back surface 1b of the seat pad, it branches into two so as to be separated from each other in the vehicle width direction. The branched hook-shaped portions 3 turn toward the vehicle traveling direction when approaching the side portions 13, respectively, extend to the vicinity of the front edge of the seat pad 1, and branch in the vehicle width direction at the middle and at the tip. Form separate parts.

The flange 3 is provided with an air outlet 31a in alignment with the respective depressions 11 for the air outlet 10 formed on the seat pad surface 1a (FIG. 4). A plurality of air outlets 10 are provided on the surface of the seat pad 1 to send air-conditioned air to a seated occupant. The air outlets 31 a connected to the air outlets 10 via the depressions 11 Provided on the bottom wall 31.
Further, a plurality of through-holes 31b are provided in the saddle-like portion 3 at a portion corresponding to the seat pad surface 1a side. The through hole 31b may be a side wall 32 close to the bottom wall 31 corresponding to the seat pad surface 1a side, but in the present embodiment, the through hole 31b is spaced from the bottom wall 31 as shown in FIGS. Provided.

Here, the flow path main member 2 is a thermoplastic synthetic resin product made of polypropylene resin, polyethylene resin or the like, but has poor adhesion to the seat pad 1 made of urethane foam or the like. Further, in order to obtain a comfortable cushioning property of the seat pad 1, the flow path main member 2 is disposed along the seat pad back surface 1b, so that the flow path main member 2 is lifted by elastic deformation of the seat pad 1 due to passenger seating or the like. There is a fear. Therefore, the backing material 6 having adhesiveness with the seat pad 1 covers the flow path main member 2 including the inner surface 3b of the bowl-shaped portion 3, and is integrally attached to the rear surface 1b by foam molding of the seat pad 1. Thus, the flow path main member 2 is prevented from being separated from the seat pad 1.
However, when the seat pad 1 with the flow path main member 2 is completed, assembled to the vehicle, and put in use, the portion of the backing material 6 that covers the inner surface 3b of the bowl-shaped portion 3 is the chain line in FIG. As shown in the figure, it hangs down and obstructs ventilation of the flow path u created by the flow path main member 2. Increase ventilation resistance.
Such a problem is solved by providing through holes 31b in the bottom wall 31 at predetermined intervals (FIG. 1). When the through hole 31b is provided, the foaming raw material g autonomously passes through the through hole 31b and impregnates and cures the backing material 6 in the foam molding of the seat pad 1, so that the seat pad with the flow path main member 2 is provided. Even if 1 is used, the backing material 6 on the inner surface 3b of the bowl-shaped portion does not hang down. When the through hole 31b is provided, the foaming raw material g is impregnated and integrated with the backing material 6 through the through hole 31b by foam molding of the seat pad 1. In the foam molding process, the foam raw material g impregnated and integrated becomes the impregnated hardened portion 18 as shown in FIG. 4 at the through hole 31b and the bottom wall 31 around this. The impregnated and hardened portion 18 is integrated with the backing material 6 and is connected to the seat pad 1 outside the collar-like portion 3 through the through hole 31b. Even if it is in the usage condition which becomes 1a, the backing material 6 which exists in the collar-shaped part inner surface 3b does not hang down. The hole diameter of the through hole 31b only needs to be able to prevent the backing material 6 from drooping, and is smaller than the hole diameter of the air outlet 31a.

  The air introduction part 41 as the auxiliary part 4 is an introduction part for sending air for air conditioning to the bowl-like part 3. The air introduction part 41 forms an air introduction cylinder part having a cylinder opening of an air introduction port similar to those of JP 2011-110366 A, JP 2012-368 A, etc. on the back side. The air introduction part 41 is provided with an air introduction port for supplying conditioned air to the flow path main member 2. In some cases, the air introduction portion 41 can be formed in a substantially U-shaped cross section that is substantially the same as the flange portion 3 (see FIG. 11). Then, the air inlet 41 and the bowl-shaped portion 3 are closed at the opening side of the U-shaped cross section, and the air distribution outlet sub-member 5 attached so as to form the ventilation passage u is a cylinder opening serving as an air inlet. The air introduction cylinder part 51 which formed 510 can be provided. In such a case, the flow path main member 2 can be produced from its shape by injection molding, press molding, vacuum molding, or the like.

  In the flow path main member 2 of the present embodiment, a hole 32c is provided in the opposing side wall 32 of the flange portion 3 made of synthetic resin (FIG. 2). Further, the backing material 6 disposed in the hole 32c is provided with a bulging portion 65 that bulges outward from the inner surface 3b side of the both side walls 32 through the hole 32c. The presence of the hole 32c facilitates the setting of the flow path main member 2 to the upper mold 72 (details will be described later). Further, in foam molding of the seat pad 1, the foaming raw material g is impregnated and cured in the backing material 6 around the bulging portion 65 and the hole 32c, so that the backing material 6 present on the inner surface 3b of the bowl-shaped portion is the main channel. Even if the seat pad 1 with the member 2 is used, it does not hang down and can contribute in the same manner as the through hole 31b.

  As shown in FIG. 3, it is more preferable that the flow path main member 2 is integrally formed with the flange-shaped portion 3 with an outer flange 42 projecting horizontally outward from the intermediate height outer surface 3 a of the opposite side wall 32. Even if the flow path main member 2 made of polypropylene resin or the like has poor adhesion to the seat pad 1 made of urethane foam or the like, the outer rod 42 is embedded in the seat pad 1 by providing the outer rod 42. This is because integration is achieved. The deformation of the flow path main member 2 can be improved by elastic deformation of the seat pad 1 due to passenger seating or the like. In the present invention, the “intermediate height outer surface 3a of the opposing side wall 32” refers to the outer surface in the paper surface height direction of the opposing side wall 32 excluding the flange portion 43 along the seat pad back surface 1b. Point to.

  The backing material 6 is a sheet-like fabric material made of a nonwoven fabric or the like that covers the back surface 1 b of the seat pad 1 including the inner surface 3 b of the bowl-shaped portion 3. The flow path main member 2 excluding the air inlet is covered, and as shown in FIG. 1, a single cloth backing material 6 that matches the size of the seat pad back surface 1b is used. By foam molding of the seat pad 1, the backing material 6 is attached and integrated on the back surface of the seat pad 1 so as to cover at least the hook-like portion 3 of the flow path main member 2 as shown in FIG. 2.

  The backing material 6 is provided with a through hole 60 on the inner surface 3b side of the air outlet 31a in alignment with the respective depressions 11 for the air outlet 10. The seat pad 1 is electrically connected from the through hole 60 to the air outlet 10 by integral foam molding of the backing material 6 and the flow path main member 2. Here, it is more preferable that a through hole 60 having a hole diameter d6 smaller than the hole diameter d3 of the air outlet 31a is provided in the portion of the backing material 6 disposed in the air outlet 31a as shown in FIG. In the foam molding of the seat pad 1, the foaming raw material g passes through the air ejection port 31a from the seat pad surface 1a side, reaches the difference with the hole diameter d6 smaller than the hole diameter d3, and the backing material 6 protrudes into the air outlet. This is because the perforation peripheral edge portion 61 which is the difference portion is impregnated and cured. The impregnated hardened portion 19 can also contribute to preventing the backing material 6 from sagging under the use state of the sheet pad containing the flow path main member, like the impregnated hardened portion 18.

  The seat pad 1 is formed by foaming, and the air outlet 31 a and the recess 11 that matches the through hole 60 are secured at a certain depth, and the air outlet of the seat pad surface 1 a formed by the recess 11 from the through hole 60. 10 is a foam in which the flow path main member 2 and the backing material 6 are embedded and integrated so as to conduct to 10. As shown in FIG. 9, the air outlet 10 is made larger than the diameter of the air outlet 31 a and the through hole 60. In foam molding of the seat pad 1, the hook-shaped portion 3 disposed on the back surface side and the backing material 6 that covers this and covers the seat pad back surface 1 b are integrated with the seat pad 1. The reason why the hook-like portion 3 is disposed on the back surface side of the seat pad 1 is that the distance from the seat pad surface 1a to the rigid hook-like portion 3 is as large as possible to obtain cushioning and comfort by the seat pad 1. Because. In FIG. 9, the thickness h1 from the seat pad surface 1a to the bowl-shaped bottom wall 31 is set to be larger than the thickness h2 from the bowl-shaped bottom wall 31 to the seat pad back surface 1b.

In this way, the through hole 60, the air outlet 31a to the air outlet 10 are conducted, and a desired flow path main member-containing seat pad integrally formed with the flow path main member 2 and the backing material 6 is completed.
Furthermore, a lid is attached to the opening-side portion 30 of the bowl-shaped portion 3 with a plate-like (or sheet-like) air distribution flow passage sub-member 5 through the backing material 6, and the flow passage sub-member 5 And a flow path main member 2 may be used as a sheet pad with a flow path main member in which a cylindrical ventilation flow path u is formed. Since the ventilation flow path u is formed, the handling is almost the same as the ducted seat pad 1 disclosed in JP 2011-110366 A and JP 2012-368 A.
When the opening side portion 30 is closed and attached by the flow passage sub-member 5 via the backing member 6, it can be attached and fixed as shown in FIG. 3 in addition to the adhesive fixing as shown in FIG. That is, the flow path main member 2 in which the pin 43d is integrally formed on the flange portion 43 protruding from the opening edge of the bowl-shaped portion 3 is prepared, and the pin 43d is passed through the small hole 50 provided in the flow distribution flow path sub member 5. Then, the opening side portion 30 is closed with the flow passage sub-member 5, and then a crimping portion 43f can be formed and fixed to the head of the pin 43d protruding from the small hole 50 as shown in FIG.
In the figure, reference numeral 13 denotes a side portion of the seat pad 1, and reference numeral 33 denotes an end wall of the bowl-shaped portion 3.

  11 and 12 show a modified example in place of FIGS. When the ventilation path of the flow path main member 2 is shortened or when the air outlets 10 are arranged at a short pitch, as shown in FIG. This can be done without 31b. In foam molding of the seat pad 1, the foaming raw material g is impregnated and cured in the peripheral edge portion 61, and the impregnated cured portion 19 is formed with a short pitch, so that the backing material 6 of FIG.

(2) Manufacturing method of seat pad with flow distribution main member including air distribution The manufacturing method of the seat pad with flow distribution main member is a U-shaped cross section along the back surface 1b of the seat pad 1 made of foam. The flow distribution main channel member 2 having the hook-shaped portion 3 is disposed so that the opening-side portion 30 of the hook-shaped portion 3 formed on the back surface is on the back surface side, and the backing material 6 further forms the hook-like shape. This is a manufacturing method in which the seat pad 1 is integrally foam-molded with the flow path main member 2 and the backing material 6 after covering the inner surface 3b and the back surface 1b of the seat pad. Prior to production, the flow path main member 2 and the backing material 6 are prepared. The flow path main member 2 and the backing material 6 are the same as those described in (1) and will not be described in detail.

The foaming mold 7 used for manufacturing the sheet pad containing the flow path main member is a divided mold as shown in FIGS. 5 to 9 and includes a lower mold 71 (one divided mold) and an upper mold 72 (another divided mold). When the mold is closed as shown in FIGS. 6 to 7, the flow path main member 2 and the backing material 6 are integrated with each other by the mold surface 710 of the lower mold 71 and the mold surface 720 of the upper mold 72 having a large degree of dent. The cavity C of the seat pad 1 to be made is created. The front surface 1 a side of the seat pad 1 is molded with the mold surface 710 of the lower mold 71, and the rear surface 1 b side of the seat pad 1 is molded with the mold surface 720 of the upper mold 72.
The lower mold 71 is provided with a raised portion 711 that bulges various portions of the mold surface 710 into a column shape and forms a recess 11 for the air outlet 10 from which air is ejected from the seat pad surface 1a. On the other hand, the upper mold 72 is provided with a raised portion 721 as shown in FIG. The swelled portion 721 has a trapezoidal cross section substantially matching the inner surface 3b of the flange-shaped portion 3 of the flow path main member 2 as shown in the figure, and matches the position where the flange-shaped portion 3 is disposed on the seat pad back surface 1b. Thus, the upper mold surface 720 is raised. Further, a convex portion 722 protruding downward is provided at a position corresponding to the raised portion 711 on the lower surface 721a (tip surface) of the raised portion 721. In more detail, the convex portion 722 is disposed at a position corresponding to the through hole 60 and the air jet port 31 a, and a cylindrical body having a size in which the base end portion of the convex portion 722 substantially coincides with the through hole 60 of the backing material 6. It has become. The upper mold 72 is also provided with a locking portion that matches the shape of the air introducing portion 41 on the air introducing portion 41.

  Using the foaming mold 7, the flow path main member 2, and the backing material 6, the sheet pad 1 with the flow path main member 2 is manufactured as follows. The air inlet provided in the air inlet 41 is stuck and sealed with a seal tape as necessary.

First, the foaming mold 7 is brought into the mold open state. Under this mold open state, the backing material 6 and the flow path main member 2 are locked and set on the upper mold 72.
The backing material 6 is attached and set to the raised portion 721 so that the convex portion 722 penetrates the through hole 60 formed in the backing material 6. The backing material 6 in FIG. 5 is preliminarily shaped into a shape that matches the raised portion 721, but a planar sheet-like backing material 6 is used, and this is placed along the raised portion 721. You may make it let.

  Next, the flow path main member 2 is attached and set on the rising portion 721 from above the backing material 6 so that the convex portion 722 penetrates the air jet 31 a formed in the flow path main member 2. The through hole 60 formed in the backing material 6 and the air ejection port 31a formed in the bowl-shaped portion 3 are fitted into the convex portion 722 in order, and the backing material 6 and the flow path main member 2 are attached to the raised portion 721. In this embodiment, a hook-like protruding portion 723 as shown in FIG. 8 is provided on the side surface 721e of the raised portion 721. In addition, the synthetic resin flow path main member 2 attached and set to the swelled portion 721 has a hole 32c formed in the side wall 32 facing the protruding portion 723. After the backing material 6 is attached to the swelled portion 721 in FIG. 8 (a), the flow channel main member 2 made of synthetic resin is flexible in the adherent set of the flow passage main member 2 to the swelled portion 721. The opening side portion 30 is widened by the elastic deformation, and the hole 32c is fitted into the protruding portion 723. As shown in FIG. Locked and held by the ascending portion 721. The backing material 6 and the flow path main member 2 are easily and reliably attached to the swelled portion 721. Then, in the adherent set of the backing material 6 and the flow path main member 2 to the swelled portion 721, the protruding portion 723 enters the hole 32c and pushes the backing material 6 to the outside of the bowl-shaped portion 3 so as to swell. A protruding portion 65 is formed.

Subsequently, while maintaining the mold open state, a foam raw material g such as a urethane foam stock solution for molding the seat pad 1 is formed on the mold surface 710 forming the cavity C of the lower mold 71 using an injection nozzle NL as shown in FIG. A predetermined amount is injected.
Subsequently, as shown in FIG. 7, the upper die 72 is operated to close the die. By closing the upper mold 72 and the lower mold 71, a cavity C for the seat pad 1 in which the flow path main member 2 is insert-set is formed. By closing the mold, the projecting end surface 722a of the convex portion 722 of the upper mold 72 is brought into contact with the raised surface 711a of the lower mold 71. With this contact, the air outlet 10 is conducted from the through hole 60 and the air outlet 31a. It becomes a type | mold structure which makes the seat pad 1. FIG.

  After closing the mold, the process proceeds to foam molding of the seat pad 1. The mold closing state of FIG. 7 is maintained for a predetermined time, the flow path main member 2 is embedded and integrated, and the sheet pad 1 on which the backing material 6 is attached and integrated on the sheet pad back surface 1b together with the flange inner surface 3b. Foam molding. In this foam molding, when the outer flange 42 is provided on the intermediate height outer surface 3a of the opposing side wall 32 related to the flange-shaped portion 3 as shown in FIG. 3, the flow path main member 2 and the seat pad 1 are integrally strengthened. More preferably.

And since the through-hole 31b is provided in the bottom wall 31 of the bowl-shaped part 3, the foaming raw material g enters the backing material 6 through the through-hole 31b and impregnates in the foam molding process, and then hardens. (Figs. 2 and 4).
Further, since the hole 32c is provided in the side wall 32 of the bowl-shaped part 3, the foaming raw material g comes into contact with the bulging part 65 of the backing material 6 through the hole 32c and is impregnated and then cured and integrated. (FIG. 2). In order to make the bulging portion 65 easy to understand, FIG. 2 is a drawing in which only the tip portion of the bulging portion 65 is brought into contact and impregnated and hardened. Cured and united.
Furthermore, the hole diameter of the through hole 60 of the backing material 6 disposed in the air outlet 31a is set smaller than the hole diameter d3 of the air outlet 31a, and the convex portion 722 is formed in accordance with the hole diameter of the through hole 60. Therefore, in foam molding of the seat pad 1, as shown in FIGS. 4 and 9, the foaming raw material g passes from the main portion 12 through the air ejection port 31a and protrudes toward the through hole 60 from the air ejection port 31a. After being impregnated by contacting with the peripheral edge portion 61 of the through hole, it is cured and integrated.
The seat pad 1 is foam-molded in a state where the flow path main member 2 and the backing material 6 are inserted into the foaming mold 7. As described above, the foam-molded foam pad 7 has a through hole 31 b, a hole 32 c, and an air outlet. As for 31a, the foaming raw material g is impregnated and cured in the backing material 6 around them, and the backing material 6 is held in close contact with the bowl-shaped portion 3.

  When foam molding of the seat pad 1 is finished and removed, the air outlets 31a and the through holes 60 are aligned with the plurality of air outlets 10 formed on the surface 1a. A product of the seat pad 1 with the flow path main member 2 that conducts up to 10 is obtained. The portions of the backing material 6 applied to the through holes 31b and the through holes 32c and the impregnated and hardened portions 18 and 19 of the foam that are impregnated and integrated with the through-hole peripheral portion 61 are the foam of the seat pad 1 and the backing material 6 at the portions. And combine. Therefore, even if the seat pad 1 with the flow path main member 2 is used in the state of being incorporated in the vehicle, the desired quality stable flow path main member 2 is entered without the backing material 6 hanging down as shown in FIG. The seat pad 1 is completed.

The seat pad 1 with the flow path main member 2 is provided with a plate-shaped (or sheet-shaped) flow distribution path on the opening side portion 30 of the bowl-shaped portion 3 through the backing material 6 before assembling to the vehicle. The sub-member 5 is closed and fixed, and a cylindrical ventilation channel u is formed with the channel main member 2. By forming the ventilation flow path u, the flow path main member 2 functions in the same manner as the duct related to the duct-containing seat pad 1 disclosed in Japanese Patent Laid-Open Nos. 2011-110366 and 2012-368. If a seat cushion with a skin (not shown) is attached to the vehicle, the air-conditioning air connected to the air blowing unit (not shown) and sent to the air introduction section 41 passes through the air holes 60 and the air outlets 31a. Air is smoothly and reliably distributed from the outlet 10 to the passenger seated on the seat cushion. Of course, at the stage of product shipment, the opening side portion 30 of the bowl-shaped portion 3 is covered with the flow path sub member 5 via the backing material 6, and the flow path sub member 5 and the flow path main member 2 Alternatively, a sheet pad containing a main channel member in which the ventilation channel u is formed may be used.
In the drawing, reference numeral K12 indicates a main part forming part, reference numeral K13 indicates a side part forming part, and reference numerals 719 and 729 indicate mold matching surfaces.

  When the ventilation path of the flow path main member 2 is shortened or when the air outlets 10 are arranged at a short pitch, the hole diameter d6 is made smaller than the hole diameter d3 as shown in FIG. By providing, the through hole 31b can be omitted. When the through hole peripheral portion 61 is provided, the foaming raw material g passes through the air jet port 31a from the seat pad surface 1a side and reaches the through hole peripheral portion 61 by foam molding of the seat pad 1 after mold closing. Impregnate and cure. The impregnated hardened portion 19 plays the same role as the impregnated hardened portion 18 by the through holes 31b for preventing the backing material 6 of FIG.

(3) Effect According to the seat pad including the flow distribution main channel member configured as described above and the manufacturing method thereof, since the flow channel u is formed by the rigid synthetic resin flow channel main member 2, Patent Document 1 Thus, it is possible to avoid a situation in which the flow rate is deformed due to the seating of the occupant and the necessary flow rate cannot be secured. If a cylindrical ventilation channel u is formed by simply closing the opening side portion 30 of the bowl-shaped portion 3 related to the seat pad 1 containing the channel main member 2 with the channel sub-member 5 via the backing material 6. The air-conditioning air that is comfortable for the passenger can be distributed easily and reliably, and the seat pad includes a main member for air distribution channel that maintains stable quality.

On the other hand, even if the rigid flow path main member 2 is provided on the seat pad 1, the flow path main member 2 has the hook-shaped portion 3 along the back surface 1 b of the seat pad 1 with the opening side portion 30 on the back surface side. Since the thickness h1 made of a foam from the seat pad surface 1a to the bowl-shaped bottom wall 31 can be increased, the occupant seated on the seat cushion hits the rigid flow path main member 2 and feels uncomfortable. I don't remember.
Here, a thermoplastic synthetic resin product such as a polypropylene resin having poor adhesion to the seat pad 1 made of urethane foam or the like may be employed for the flow path main member 2. In such a case, there is a possibility that the flow path main member 2 may be lifted due to elastic deformation of the seat pad 1 due to occupant seating or the like, but the inner surface 3b of the bowl-shaped portion 3 and the back surface 1b of the seat pad 1 are backed by a single piece. Since the material 6 covers and the backing material 6 is integrally foam-molded with the seat pad 1, the flow path main member 2 is prevented from being peeled off. However, when the seat pad 1 containing the flow path main member 2 is installed and installed in the vehicle, the portion of the backing material 6 on the inner surface 3b of the bowl-shaped portion 3 hangs down. Although this sagging hinders the air-conditioning flow path as shown by the chain line in FIG. 10, the present invention solves the through hole 31b, the through hole peripheral portion 61, and the through hole 32c.
As in the present invention, when a plurality of through-holes 31b are provided at a portion of the hook-shaped portion 3 on the seat pad surface 1a side, a foaming raw material g is autonomously formed by foam molding of the seat pad 1 and the through-holes 31b. The backing material 6 is impregnated and cured. Separately, without impregnating with an adhesive or the like, the impregnated hardened portion 18 of the foam raw material g impregnated and integrated with the backing material 6 is bonded to the main body of the seat pad 1 through the through hole 31b. The problem of sagging at the site can be solved. If a plurality of the through holes 31b are provided at an appropriate pitch, the backing material 6 does not hang down in the ventilation channel u to increase the ventilation resistance.

Further, when a through hole 60 having a hole diameter d6 smaller than the hole diameter d3 of the air outlet 31a is provided, the impregnated and hardened portion 19 of the foam that is impregnated and integrated into the peripheral edge portion 61 by foam molding of the seat pad 1 is provided. Since it is combined with the foam of the seat pad 1, the backing material 6 comes into contact with and is held by the inner surface 3 b of the hook-shaped portion 3 around it, and the problem of drooping can be solved like the through hole 31 b. .
In addition, a hole 32c is provided in the opposite side wall 32 of the bowl-shaped portion 3, and the backing material 6 disposed in the hole 32c bulges outwardly from the inner surface 3b side of both side walls 32 through the hole 32c. When the portion 65 is provided, the impregnated hardened portion of the foam that is impregnated and integrated with the backing material 6 around the bulging portion 65 and the hole 32c is combined with the foam of the seat pad 1 by foam molding of the seat pad 1. Also, the backing material 6 comes into contact with and is held by the inner surface 3b of the bowl-like portion 3 even around it, and the problem of drooping can be solved. Further, when the hole 32c is formed, if the protruding portion 723 is provided at a position opposite to the upper mold 72, the protruding portion 723 is attached to the backing material 6 and the bulging portion 721 of the flow path main member 2. Enters the hole 32c and extrudes the backing material 6 to the outside of the flow path main member 2 to form the bulging portion 65, and the flow path main member 2 can be locked and held in the upper mold 72. The flow channel main member 2 and the backing material 6 can be easily attached to the mold 7.

In addition, when an outer flange 42 projecting outward is integrally formed on the flange-shaped portion 3 on the outer surface of the intermediate height of the opposite side wall 32 of the flange-shaped portion 3, the outer flange 42 is formed in the seat pad 1 by foam molding. Since it is buried, it contributes to preventing the flow path main member 2 from being peeled off together with the backing material 6.
Further, unlike the duct forming the ventilation flow path u found in JP 2011-110366 A, JP 2012-368 A, etc., the hook-like portion 3 is integrated with the seat pad 1. A sufficient foam thickness h1 from the seat pad surface 1a to the bowl-shaped bottom wall 31 can be secured. Recently, the thickness of the seat pad 1 has been reduced, and there are cases where the dimensions in the duct thickness direction cannot be obtained as desired, but even in such a case, the present invention can be handled, so that it can be handled as a seat pad capable of air distribution. Wide application range.
Further, the opening-side portion 30 of the bowl-shaped portion 3 is attached with a cover with a sheet-like or plate-like channel sub-member 5 via the backing material 6, and the channel sub-member 5 and the channel main member 2 are attached. If a sheet pad with a main flow distribution channel member is formed with a cylindrical ventilation channel u, a product with the same ventilation channel u as that of JP 2011-110366 A can be produced at low cost. it can.
Further, as shown in FIG. 11, when the flow passage main member 2 formed with the air introduction portion 41 having the substantially same U-shaped cross section as that of the flange-like portion 3 is employed, the flow passage main member 2 is press-molded in addition to injection molding. Or by vacuum forming or the like, and further cost reduction can be achieved.

  The present invention is not limited to those shown in the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, and the like of the seat pad 1, the flow channel main member 2, the air introduction part 41, the flow channel sub member 5, the backing material 6, the foaming mold 7, and the like can be appropriately selected according to the application. In the embodiment, the seat pad 1 is applied to the cushion pad, but it can also be applied to the back pad.

1 Seatpad 1a Surface (Seatpad surface)
1b Back side (Seat pad back side)
DESCRIPTION OF SYMBOLS 10 Air blower outlet 11 Depression 2 Flow path main member 3 Gutter-like part 3b Inner surface (gear-like inner surface)
31 Bottom wall 31a Air outlet 32 Side wall 32c Hole 42 Outer flange 5 Channel sub member 6 Backing material 60 Through hole 65 Swelling portion 71 One split type (lower type)
710 Mold surface 711 Raised portion 72 Other split mold (upper mold)
722 Convex part 723 Protrusion part g Foaming raw material u Ventilation flow path (flow path)

Claims (7)

A sheet pad made of a foam, and a channel main member for air distribution in which a hook-shaped portion formed in a U-shaped cross section along the back surface of the seat pad is disposed with the opening side portion on the back surface side, A backing material that covers the inner surface of the bowl-shaped portion and the back surface of the seat pad, and the seat pad is integrally formed with the flow path main member and the backing material, and is formed on the surface of the seat pad. In addition to aligning with the recess for the air outlet, an air outlet is provided in the flow path main member and a through hole is provided in the backing material, so that conduction from the through hole to the air outlet is established. A plurality of through-holes are provided in the saddle-like portion at a portion corresponding to the surface side of the seat pad, and foaming of the seat pad impregnates the backing material through the through-holes, A seat pad containing a flow distribution main member, which is cured. The sheet with the flow distribution main member for air distribution according to claim 1, wherein the through hole having a hole diameter smaller than the hole diameter of the air outlet is provided in a portion of the backing material arranged in the air outlet. pad. The sheet containing the flow path main member for air distribution according to claim 1 or 2, wherein an outer flange projecting outward is integrally formed on the outer surface at an intermediate height of the opposing side wall of the flange-shaped portion. pad. A hole is provided in the opposite side wall of the flange-shaped portion made of synthetic resin, and a bulging portion that bulges outward from the inner surface side of both side walls through the hole is provided in the backing material arranged in the hole. The seat pad with a flow path main member for air distribution according to any one of claims 1 to 3. The opening-side portion of the bowl-shaped portion is attached with a cover with a sheet-like or plate-like air flow distribution sub member through the backing material, and the air flow distribution sub member and the flow channel main member are attached. The seat pad with a flow distribution main member according to any one of claims 1 to 4, wherein a cylindrical ventilation flow channel is formed with the member. A main channel member for air distribution having the hook-shaped portion so that the opening-side portion of the hook-shaped portion formed in a U-shaped cross section is on the back surface side along the back surface of the foamed seat pad. And further covering the inner surface of the bowl-shaped portion and the back surface of the seat pad with a fabric backing material, and the air distribution flow path integrally foamed with the flow path main member and the backing material. A method for manufacturing a seat pad containing a main member,
Consists of split molds, one split mold is provided with a raised portion that forms a recess for an air outlet from which air is ejected from the surface of the seat pad, while the other split mold is provided with a raised portion, and Using a foaming mold provided with a protruding part protruding on the tip surface of the swelled part,
The through hole formed in the backing material and the air jet port formed in the bowl-shaped portion are sequentially fitted to the convex portion, and the backing material is attached and set to the raised portion, and the seat pad surface The plurality of flow path main members provided with a plurality of through holes spaced apart from each other on the side of the flange-like portion are attached and set, and then the mold is closed. After that, the protruding end surface of the convex portion abuts against the tip of the raised portion. A sheet pad electrically connected to the air outlet from the through hole is integrally foam-molded with the flow path main member and the backing material, and the foaming raw material is formed by foaming the seat pad. A method for producing a seat pad containing a flow distribution main member for air distribution, wherein the backing material is impregnated and cured. A flange-shaped protrusion is further formed on the side surface of the raised portion, and the flow passage main member made of synthetic resin is attached and set to the raised portion, and a hole is formed in a side wall facing the protruding portion. And
In the adherent set of the backing material and the flow path main member to the swelled portion, the protruding portion enters the hole and pushes the backing material outward of the flow path main member. The manufacturing method of the seat pad containing the flow path main member for air distribution according to claim 6 formed.

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