JP6997569B2

JP6997569B2 - How to make a seat pad for a vehicle

Info

Publication number: JP6997569B2
Application number: JP2017183039A
Authority: JP
Inventors: 真人松本
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 2017-09-22
Filing date: 2017-09-22
Publication date: 2022-01-17
Anticipated expiration: 2037-09-22
Also published as: JP2019058214A

Description

この発明は、成形型内で発泡原料を発泡させることにより発泡体からなるパッド基材を形成する車両用のシートパッドの製造方法に関するものである。 The present invention relates to a method for manufacturing a seat pad for a vehicle, which forms a pad base material made of a foam by foaming a foaming raw material in a molding die.

乗用車等の乗員室内に設置されるシート１００は、例えば図１２に示すように、着座した乗員の下半身を支えるシートクッション１０２と、このシートクッション１０２の後部に傾動可能に設置されて乗員の上半身を支えるシートバック１０４と、シートバック１０４の上部に設置されて乗員の頭部を保護するヘッドレスト１０６とを備えるよう構成されていることが一般的である。このようなシートクッション１０２やシートバック１０４は、ポリウレタンフォーム等の発泡樹脂部材により形成されたシートパッドの表面をファブリックや合成皮革または皮革等の表皮材により形成されたシートカバーで覆う(カバーリングする)ように形成されている(例えば特許文献１)。 As shown in FIG. 12, for example, the seat 100 installed in the passenger compartment of a passenger car or the like has a seat cushion 102 that supports the lower body of the seated occupant and a seat cushion 102 that is tiltably installed at the rear of the seat cushion 102 to provide the upper body of the occupant. It is generally configured to include a supporting seat back 104 and a headrest 106 installed on top of the seat back 104 to protect the occupant's head. Such a seat cushion 102 or a seat back 104 covers (covers) the surface of a seat pad formed of a foamed resin member such as polyurethane foam with a seat cover formed of a fabric or a skin material such as synthetic leather or leather. ) (For example, Patent Document 1).

特許第５２０３６９１号公報Japanese Patent No. 5203691

ここで、シートカバーは、所要のデザイン形状に形成したシートパッドに対して弛みがないように張設することが求められることから、前記特許文献１のように、ファブリックや合成皮革または皮革等の表皮材を縫製して袋状に形成するよう形成されたシートカバーの縫い代を、シートパッドに形成されたホグリング用の溝に引き込むことにより、シートパッドの表面形状に対して弛みなく張設される。このような袋状のシートカバーをシートパッドに被せる際や、表皮材の縫い代をホグリング用の溝に引き込む際に、シートパッドの外周縁が変形してしまうと、シートパッドのデザインが損なわれてしまう。このようなシートパッドの変形は、前述した特許文献１のように、シートパッドの上端部や側部等のシートパッドの外周縁側を構成する発泡樹脂部材の剛性を高くすることで抑制することができる。しかしながら、シートパッドを構成する発泡樹脂部材の硬度を完全に制御して製造することは極めて困難で、発泡体の硬度にばらつきが必然的に生じることから、カバーリング時のシートパッドの変形を完全に防止することは困難である。また、シートパッド自体が発泡樹脂部材により構成されるため、その弾性的な変形を防ぐことはできないことから、カバーリング時のシートパッドの変形を完全に防止することは困難である。このようなシートパッドの変形を防止するために、カバーリングを行う際にシートパッドの変形し易い部分に別に用意した部品を接着等してその剛性を高めることが行われているが、作業工数が増大するばかりでなく、作業者毎に部品の取付精度にばらつきが生じ、一定の品質を維持できない問題が発生することが懸念される。 Here, since the seat cover is required to be stretched so as not to be loosened with respect to the seat pad formed in the required design shape, as in Patent Document 1, the fabric, synthetic leather, leather, or the like is used. By pulling the seam allowance of the seat cover formed so as to sew the skin material into a bag shape into the groove for hog ring formed in the seat pad, the seat cover is stretched without slack with respect to the surface shape of the seat pad. .. If the outer peripheral edge of the seat pad is deformed when such a bag-shaped seat cover is put on the seat pad or when the sewing allowance of the skin material is pulled into the groove for hog ring, the design of the seat pad is impaired. It ends up. Such deformation of the seat pad can be suppressed by increasing the rigidity of the foamed resin member constituting the outer peripheral edge side of the seat pad such as the upper end portion and the side portion of the seat pad, as in Patent Document 1 described above. can. However, it is extremely difficult to completely control the hardness of the foamed resin member constituting the seat pad, and the hardness of the foam inevitably varies. Therefore, the seat pad is completely deformed during covering. It is difficult to prevent. Further, since the seat pad itself is made of a foamed resin member, it is not possible to prevent its elastic deformation, so that it is difficult to completely prevent the deformation of the seat pad at the time of covering. In order to prevent such deformation of the seat pad, parts prepared separately are adhered to the easily deformable part of the seat pad when covering to increase the rigidity, but the work man-hours are increased. Not only the number of parts increases, but also the mounting accuracy of parts varies from worker to worker, and there is a concern that a problem that a certain quality cannot be maintained may occur.

また、近年は、シートデザインに対する要求の高まりを受け、シートパッドを複雑な曲面形状を有する立体形状に形成されることがあり、このようなケースではシートパッドの変形が起き易くなる。またシートパッドのデザイン性が高まるにつれ、肉厚が部分的に極めて薄くなる立体形状に形成されることがあり、このような場合は、カバーリング時のシートパッドの変形に限らず、例えば乗員によりシートパッドの外周縁が押されるなどによってシートパッドの変形を生じ易い問題が指摘される。 Further, in recent years, in response to increasing demands for seat design, the seat pad may be formed into a three-dimensional shape having a complicated curved surface shape, and in such a case, the seat pad is likely to be deformed. Further, as the design of the seat pad is improved, the wall thickness may be partially formed into a three-dimensional shape, which is not limited to the deformation of the seat pad at the time of covering, for example, by the occupant. It has been pointed out that the seat pad is likely to be deformed due to the outer peripheral edge of the seat pad being pressed.

すなわち本発明は、パッド基材の変形を効果的に防止し得る車両用のシートパッドの製造方法を提供することを目的とする。 That is, an object of the present invention is to provide a method for manufacturing a seat pad for a vehicle, which can effectively prevent deformation of the pad base material.

前記課題を解決し、所期の目的を達成するため、本願の請求項１に係る発明は、
複数の分割型で構成した成形型内で発泡原料を発泡させることにより発泡体からなるパッド基材を形成するようにした車両用のシートパッドの製造方法において、
前記パッド基材の湾曲した外周縁に倣うよう形成した補強部材に設けた突出部の突出端部で開口する嵌合孔を、前記成形型を構成する嵌合突部を形成した分割型の当該嵌合突部に嵌合させて、当該突出部の突出端部が当該分割型の成形面に当接した状態で当該補強部材を設置し、
前記成形型の型閉めにより前記嵌合突部を形成した分割型と対向する別の分割型に設けた係合突部を前記補強部材に当接させて、当該嵌合突部を形成した分割型と当該係合突部とにより当該補強部材を挟持し、
前記補強部材を挟持した状態で、前記成形型内で発泡原料を発泡させて前記パッド基材を形成し、
前記パッド基材を前記成形型から脱型することで、湾曲した外周縁に沿うよう外表面側に前記補強部材が埋設された状態で当該補強部材の前記嵌合孔が外表面で開口するシートパッドを製造するようにしたことを要旨とする。
このように、パッド基材の外周縁に沿うよう補強部材を外表面側に埋設したシートパッドを製造することができるから、パッド基材を剛性の高い高密度な発泡樹脂部材から形成することなく、パッド基材の剛性を高め外周縁が変形するのを効果的に防止することができる。更に、パッド基材に補強部材を埋設することで、変形を防止する部材を別に取り付ける必要がないから、作業工数を低減できると共に一定の品質を維持することができる。
また、補強部材の嵌合孔を分割型に設けた嵌合突部に嵌合して、当該嵌合突部を形成した分割型と別の分割型に設けた係合突部とにより補強部材を挟持することで、成形型内で位置ずれすることなく補強部材を位置決めすることができ、パッド基材において変形防止が求められる部位に補強部材を正確に配置することができる。このとき、嵌合突部を嵌合孔に嵌合することにより、当該嵌合孔をパッド基材の外表面に開口させることができるから、シートパッドを装飾する装飾部材等を容易に取り付けることができる。
更に、補強部材を挟持することで、当該補強部材において嵌合孔を設けた突出部の突出端部を分割型の成形面に密着させることができるから、当該嵌合孔の内部に発泡原料が侵入するのを防ぐことができ、発泡原料を発泡させることで形成される発泡体により嵌合孔が塞がれるのを防止できる。 In order to solve the above-mentioned problems and achieve the intended purpose, the invention according to claim 1 of the present application is used.
In a method for manufacturing a seat pad for a vehicle in which a pad base material made of a foam is formed by foaming a foaming raw material in a molding mold composed of a plurality of split molds.
The fitting hole opened at the protruding end of the protruding portion provided in the reinforcing member formed to imitate the curved outer peripheral edge of the pad base material is the split type in which the fitting protrusion constituting the molding mold is formed. The reinforcing member is installed in a state where it is fitted to the fitting protrusion and the protruding end of the protruding portion is in contact with the molding surface of the split type.
The split mold having the fitting protrusion formed by closing the mold with the engaging protrusion provided in another split mold facing the split mold is brought into contact with the reinforcing member to form the fitting protrusion. The reinforcing member is sandwiched between the mold and the engaging protrusion,
With the reinforcing member sandwiched, the foaming raw material is foamed in the molding mold to form the pad base material.
By removing the pad base material from the molding die, a sheet in which the fitting hole of the reinforcing member is opened on the outer surface in a state where the reinforcing member is embedded on the outer surface side along the curved outer peripheral edge. The gist is that we started to manufacture pads.
In this way, it is possible to manufacture a seat pad in which a reinforcing member is embedded on the outer surface side along the outer peripheral edge of the pad base material, so that the pad base material is not formed from a highly rigid and high-density foamed resin member. , The rigidity of the pad base material can be increased and the outer peripheral edge can be effectively prevented from being deformed. Further, by embedding the reinforcing member in the pad base material, it is not necessary to separately attach a member for preventing deformation, so that the work man-hours can be reduced and a certain quality can be maintained.
Further, the fitting hole of the reinforcing member is fitted into the fitting protrusion provided in the split mold, and the reinforcing member is formed by the split mold in which the fitting protrusion is formed and the engagement protrusion provided in another split mold. By sandwiching the above, the reinforcing member can be positioned without shifting in the molding die, and the reinforcing member can be accurately arranged at a portion of the pad base material where deformation prevention is required. At this time, by fitting the fitting protrusion into the fitting hole, the fitting hole can be opened on the outer surface of the pad base material, so that a decorative member or the like for decorating the seat pad can be easily attached. Can be done.
Further, by sandwiching the reinforcing member, the protruding end portion of the protruding portion provided with the fitting hole in the reinforcing member can be brought into close contact with the molded surface of the split type, so that the foamed raw material can be placed inside the fitting hole. It is possible to prevent intrusion, and it is possible to prevent the fitting hole from being blocked by the foam formed by foaming the foaming raw material.

請求項２に係る発明は、
前記成形型を型閉めした状態で、前記嵌合突部に前記嵌合孔が嵌合する嵌合位置から偏倚して延在する前記補強部材の補強部に対して、前記成形型を構成する何れかの前記分割型に設けた位置規制突部を当該補強部の前記嵌合突部を形成した分割型の前記成形面の他端側の縁部に当接させた状態で、前記成形型内で発泡原料を発泡させるようにしたことを要旨とする。
このように、嵌合位置から偏倚して延在する補強部材の補強部に対して、位置規制突部を当該補強部の嵌合突部を形成した分割型の成形面の他端側の縁部に当接させることで、発泡原料を発泡した際の発泡圧により補強部材がずれるのを防ぐことができ、パッド基材において変形防止が求められる部位に補強部材を配置することができる。 The invention according to claim 2 is
With the molding die closed, the molding die is formed with respect to the reinforcing portion of the reinforcing member extending deviated from the fitting position where the fitting hole is fitted to the fitting protrusion. The molding die in a state where the position-regulating protrusion provided on any of the split dies is in contact with the edge on the other end side of the molding surface of the split die forming the fitting protrusion of the reinforcing portion. The gist is that the foaming material is foamed inside.
In this way, with respect to the reinforcing portion of the reinforcing member that extends unevenly from the fitting position, the position-regulating protrusion is the edge on the other end side of the split-type molding surface that forms the fitting protrusion of the reinforcing portion. By abutting on the portion, it is possible to prevent the reinforcing member from shifting due to the foaming pressure when the foamed raw material is foamed, and it is possible to arrange the reinforcing member at a portion of the pad base material where deformation prevention is required.

請求項３に係る発明は、
前記嵌合突部を形成した分割型において前記パッド基材の本体部を成形する第１の成形面の一端側に、当該第１の成形面より上方に位置して当該パッド基材における本体部の上部後方に位置する後側支持壁部を成形する第２の成形面を設けると共に、当該第２の成形面の一側部に、当該第２の成形面より下方に位置して当該パッド基材における本体部の上部左側に位置する左側支持壁部を成形する第３の成形面を設け、当該第２の成形面の他側部に、当該第２の成形面より下方に位置して当該パッド基材における本体部の上部右側に位置する右側支持壁部を成形する第４の成形面を設けるよう構成し、
前記第２の成形面における前記第１成形面から離間する端縁部、前記第３の成形面および第４の成形面における前記第２の成形面から離間する下縁部に沿って延在するよう前記補強部材を設置し、
前記成形型内で発泡原料を発泡させた前記パッド基材を前記成形型から脱型することで、前記本体部の上部に形成された上方および前方に開放する凹形状のヘッドレスト装着部の前方の開口縁および上方の開口縁に沿って前記補強部材を埋設するようにしたことを要旨とする。
このように、ヘッドレスト装着部の前方の開口縁および上方の開口縁に倣う形状に形成した補強部材を埋設することで、ヘッドレスト装着部の形状保持性を高めつつシートパッドのデザイン性を向上することができる。 The invention according to claim 3 is
In the split mold in which the fitting protrusion is formed, the main body portion of the pad base material is located above the first molding surface on one end side of the first molding surface for molding the main body portion of the pad base material. A second molding surface for molding the rear support wall portion located behind the upper part of the pad base is provided, and the pad base is located on one side of the second molding surface below the second molding surface. A third molding surface for molding the left side support wall portion located on the upper left side of the main body portion of the material is provided, and the other side portion of the second molding surface is located below the second molding surface. A fourth molding surface for molding the right support wall portion located on the upper right side of the main body portion of the pad base material is provided.
It extends along the edge portion of the second molding surface that is separated from the first molding surface, the third molding surface, and the lower edge portion of the fourth molding surface that is separated from the second molding surface. Install the reinforcing member
By removing the pad base material from which the foamed raw material is foamed in the molding die from the molding die, the front of the concave headrest mounting portion formed on the upper part of the main body portion and opened upward and forward. The gist is that the reinforcing member is embedded along the opening edge and the upper opening edge.
In this way, by embedding a reinforcing member formed in a shape that imitates the front opening edge and the upper opening edge of the headrest mounting portion, the design of the seat pad can be improved while improving the shape retention of the headrest mounting portion. Can be done.

請求項４に係る発明は、
前記第１の成形面に形成した前記嵌合突部に前記嵌合孔を嵌合させて、前記突出部の突出端部が前記第１の成形面の成形面に当接した状態で前記補強部材を設置し、
前記成形型を型閉めした状態で、前記第２の成形面における前記第１の成形面から離間する端縁部に沿って延在する前記補強部材の前記補強部に対して、前記成形型を構成する何れかの前記分割型に設けた前記位置規制突部を当該補強部の前記第１の成形面の他端側の縁部に当接させた状態で、前記成形型内で発泡原料を発泡させるようにしたことを要旨とする。
このように、嵌合位置から偏倚して延在する補強部材の補強部に対して、位置規制突部を当該補強部の第１の成形面の他端側の縁部に当接させることで、発泡原料を発泡した際の発泡圧により補強部材がずれるのを防ぐことができ、ヘッドレスト装着部において変形防止が求められる部位に補強部材を正確に配置することができる。 The invention according to claim 4 is
The fitting hole is fitted into the fitting protrusion formed on the first molding surface, and the reinforcing end is in contact with the molding surface of the first molding surface. Install the parts,
With the molding die closed, the molding die is applied to the reinforcing portion of the reinforcing member extending along the edge portion of the second molding surface separated from the first molding surface. In a state where the position-regulating protrusion provided in any of the constituent split molds is in contact with the edge of the reinforcing portion on the other end side of the first molding surface, the foaming raw material is placed in the molding die. The gist is that it is made to foam.
In this way, the position-regulating protrusion is brought into contact with the edge of the reinforcing member on the other end side of the first molded surface of the reinforcing portion with respect to the reinforcing portion of the reinforcing member that extends unevenly from the fitting position. It is possible to prevent the reinforcing member from shifting due to the foaming pressure when the foamed raw material is foamed, and it is possible to accurately arrange the reinforcing member at a portion of the headrest mounting portion where deformation prevention is required.

請求項５に係る発明は、
前記成形型の型閉めした際に、前記突出部において前記嵌合孔と反対側で開口する開口部を、前記係合突部により塞ぐようにしたことを要旨とする。
このように、突出部において嵌合孔と反対側で開口する開口部を係合突部により塞ぐことで、当該開口部をシール材等により塞ぐ必要がなく、作業工数を低減できる。 The invention according to claim 5 is
The gist is that when the mold is closed, the opening of the protruding portion that opens on the opposite side of the fitting hole is closed by the engaging protrusion.
In this way, by closing the opening that opens on the opposite side of the fitting hole in the protruding portion with the engaging protrusion, it is not necessary to close the opening with a sealing material or the like, and the work man-hours can be reduced.

本発明によれば、パッド基材の変形を効果的に防止可能なシートパッドを製造することができる。 According to the present invention, it is possible to manufacture a seat pad capable of effectively preventing deformation of the pad base material.

本発明のシートパッドからヘッドレストを分離した状態を示す正面図である。It is a front view which shows the state which separated the headrest from the seat pad of this invention. シートパッドにおけるヘッドレスト装着部を拡大して示す要部拡大正面図である。It is an enlarged front view of the main part which shows the headrest mounting part in the seat pad in an enlarged manner. シートパッドにおけるヘッドレスト装着部を拡大して示す要部拡大平面図である。It is an enlarged plan view of the main part which shows the headrest mounting part in the seat pad in an enlarged manner. (a)は補強部材の正面図であり、(b)は補強部材の平面図である。(a) is a front view of the reinforcing member, and (b) is a plan view of the reinforcing member. 補強部材を後方右下方から見た状態で示す斜視図である。It is a perspective view which shows the reinforcing member as seen from the rear right lower part. 補強部材の第１の支持片の形成位置でシートパッドを縦断した切断部端面図である。It is an end view of the cut portion which longitudinally cut through the seat pad at the formation position of the 1st support piece of a reinforcing member. 型開きした成形型に補強部材を設置する状態を示す概略で示す断面図である。It is sectional drawing which shows schematicly which shows the state which installs the reinforcing member in the mold which opened the mold. 補強部材を設置した成形型を型閉めした状態を示す概略で示す断面図である。It is sectional drawing which shows schematicly which shows the state which the molding die which installed the reinforcing member is closed. 図８の一端側の要部拡大図である。It is an enlarged view of the main part on one end side of FIG. 補強部材を設置した成形型を、図４におけるＡ－Ａ線に相当する位置で縦断した状態を概略で示す断面図である。It is sectional drawing which shows roughly the state which the molding die which installed the reinforcing member is longitudinally crossed at the position corresponding to the line AA in FIG. 別実施例に係る成形型を型閉めした状態で、図４におけるＡ－Ａ線に相当する位置で縦断した状態を概略で示す要部拡大図である。FIG. 5 is an enlarged view of a main part schematically showing a state in which a molding die according to another embodiment is vertically cut at a position corresponding to the line AA in FIG. 4 in a state where the mold is closed. 車両用のシートを示す斜視図である。It is a perspective view which shows the seat for a vehicle.

次に、本発明に係る車両用のシートパッドの製造方法につき、好適な実施例を挙げて、添付図面を参照して以下に説明する。なお、車両用のシートパッドとして、乗用車等の乗員室内に設置されるシートのシートバックに用いられるものを例にして説明するが、これに限られるものではない。なお、本発明において、シートパッドを基準として乗員の背中を支持する支持面側を「前」とすると共に当該支持面の裏側を「後」とする。また、シートパッドに乗員が着座した際の乗員の右腕側となる側を「右」とすると共に左腕側となる側を「左」とする。 Next, a method for manufacturing a seat pad for a vehicle according to the present invention will be described below with reference to the accompanying drawings with reference to suitable examples. The seat pads for vehicles will be described by taking as an example a seat pad used for a seat back of a seat installed in a passenger car or the like, but the present invention is not limited thereto. In the present invention, the support surface side that supports the back of the occupant is referred to as "front" and the back side of the support surface is referred to as "rear" with respect to the seat pad. Further, the side on the right arm side of the occupant when the occupant sits on the seat pad is referred to as "right", and the side on the left arm side is referred to as "left".

本発明に係る製造方法により製造されるシートパッド１０は、ポリウレタン樹脂等の発泡原料をシートバックの外形形状に合わせて発泡成形させて形成されたパッド基材１２と、パッド基材１２に埋設されると共にパッド基材１２の外周縁に倣うよう形成した補強部材３０とを備えている。そして、シートの骨格を形成するシートフレームＳＦ(図６参照)に対して、全体を前側から覆うようにパッド基材１２を被せた状態でシートフレームＳＦに支持されるようになっている。このパッド基材１２は、図１に示すように、乗員の背中を主として支持する本体部１３と、本体部１３の上部に設けられて乗員の頭部を支持するヘッドレストＨＲを取り付けるヘッドレスト装着部１８とを主として備えるよう構成されている。ここで、パッド基材１２の本体部１３は、前面に形成された溝部１２ａにより乗員の上体を支持する複数のサポート部に区分するよう構成されている。具体的には、パッド基材１２は、乗員の上体を後方から支持する中央サポート部１４と、中央サポート部１４の左右側部から前方へ張り出して乗員の上体を横から支持する左右のサイドサポート部１６とを有する所謂バケットシート形状に形成されている。より細かくは、中央サポート部１４は、乗員の背中を主に支持する上側のサポート領域１４ａと、乗員の腰部周辺を主に支持する下側のサポート領域１４ｂとを有しており、左右のサイドサポート部１６の夫々は、乗員の肩周り周辺部を横から主に支持する上側のサポート領域１６ａと、乗員の腰部周辺を主に支持する下側のサポート領域１６ｂとを有するよう構成されている。そして、中央サポート部１４と左右のサイドサポート部１６の境界部分および各サポート部１４,１６における各サポート領域１４ａ,１４ｂ,１６ａ,１６ｂの境界部分に溝部１２ａを設けるよう構成され、溝部１２ａの適宜位置に、シートカバーＳＣ(図６参照)の固定用の固定部材(図示せず)が配置されている。ここで、シートカバーＳＣは、各サポート部１４,１６(サポート領域１４ａ,１４ｂ,１６ａ,１６ｂ)の形状に合わせて形成した複数の表皮材を縫い合わせることによりパッド基材１２の外表面に密着する袋状に形成され、シートカバーＳＣをパッド基材１２に被せた状態で、表皮材の縫い代を前側からパッド基材１２の溝部１２ａに引き込んで固定部材に固定することで、シートカバーＳＣをパッド基材１２に弛みなく固定し得るようになっている。 The seat pad 10 manufactured by the manufacturing method according to the present invention is embedded in a pad base material 12 formed by foaming and molding a foaming raw material such as a polyurethane resin according to the outer shape of the seat back, and the pad base material 12. It also includes a reinforcing member 30 formed to imitate the outer peripheral edge of the pad base material 12. Then, the seat frame SF (see FIG. 6) forming the skeleton of the sheet is supported by the seat frame SF in a state where the pad base material 12 is covered so as to cover the whole from the front side. As shown in FIG. 1, the pad base material 12 has a main body portion 13 that mainly supports the back of the occupant, and a headrest mounting portion 18 that is provided on the upper part of the main body portion 13 and attaches a headrest HR that supports the occupant's head. It is mainly configured to have and. Here, the main body portion 13 of the pad base material 12 is configured to be divided into a plurality of support portions that support the upper body of the occupant by the groove portions 12a formed on the front surface. Specifically, the pad base material 12 has a central support portion 14 that supports the occupant's upper body from the rear, and left and right that project forward from the left and right side portions of the central support portion 14 to support the occupant's upper body from the side. It is formed in a so-called bucket seat shape having a side support portion 16. More specifically, the central support portion 14 has an upper support area 14a that mainly supports the back of the occupant and a lower support area 14b that mainly supports the periphery of the occupant's waist, and the left and right side supports. Each of the portions 16 is configured to have an upper support region 16a that mainly supports the peripheral portion around the shoulder of the occupant from the side and a lower support region 16b that mainly supports the peripheral portion around the waist of the occupant. Then, the groove portion 12a is provided at the boundary portion between the central support portion 14 and the left and right side support portions 16 and the boundary portions of the support regions 14a, 14b, 16a, 16b in the support portions 14, 16, and the appropriate positions of the groove portions 12a are provided. A fixing member (not shown) for fixing the seat cover SC (see FIG. 6) is arranged in the seat cover SC (see FIG. 6). Here, the seat cover SC adheres to the outer surface of the pad base material 12 by sewing a plurality of skin materials formed according to the shapes of the support portions 14, 16 (support regions 14a, 14b, 16a, 16b). The seat cover SC is padded by being formed in a bag shape and having the seat cover SC covered with the pad base material 12 by pulling the seam allowance of the skin material from the front side into the groove portion 12a of the pad base material 12 and fixing it to the fixing member. It can be fixed to the base material 12 without slack.

また、ヘッドレスト装着部１８の底面には、上下に貫通するステー挿通孔２０が左右に離間する位置に設けられており、ヘッドレストＨＲから下方に延在する支持ステーＨＲａを上方からステー挿通孔２０に挿入し得るよう構成されている。なお、ステー挿通孔２０に挿通された支持ステーＨＲａは、シートフレームＳＦに設けられた図示しないステー固定部に支持されるようになっている。 Further, on the bottom surface of the headrest mounting portion 18, stay insertion holes 20 penetrating vertically are provided at positions separated from each other to the left and right, and the support stay HRa extending downward from the headrest HR is inserted into the stay insertion holes 20 from above. It is configured to be insertable. The support stay HRa inserted through the stay insertion hole 20 is supported by a stay fixing portion (not shown) provided in the seat frame SF.

ここで、このヘッドレスト装着部１８は、中央サポート部１４よりも上方に延在してヘッドレストＨＲの左右側部に対向する左右のサイドサポート部１６と、中央サポート部１４の上部において左右のサイドサポート部１６の後端部に連設する支持壁部２６とにより前方および上方に開口する凹形状に形成されている。すなわち、ヘッドレスト装着部１８にヘッドレストＨＲの下部側を収容した状態で取り付け得るようになっており、シートパッド１０とヘッドレストＨＲとが連続した一体のデザイン形状を形成するようになっている。このように、左右のサイドサポート部１６は、ヘッドレストＨＲにより支持された乗員の側頭部を支持する機能を併せ持った部位である。なお、以下の説明において、左右のサイドサポート部１６の内で、ヘッドレスト装着部１８を形成する部位を左側支持壁部２２および右側支持壁部２４と、左右のサイドサポート部１６の後端部に連設する支持壁部２６を後側支持壁部２６と特に指称する場合がある。すなわち、左側支持壁部２２がパッド基材１２の外周左側部を形成し、右側支持壁部２４がパッド基材１２の外周右側部を形成している。 Here, the headrest mounting portion 18 extends above the central support portion 14 and faces the left and right side portions of the headrest HR, and the left and right side support portions 16 at the upper part of the central support portion 14. It is formed in a concave shape that opens forward and upward by a support wall portion 26 that is continuously provided at the rear end portion. That is, it can be attached to the headrest mounting portion 18 in a state where the lower side of the headrest HR is accommodated, and the seat pad 10 and the headrest HR form a continuous integrated design shape. As described above, the left and right side support portions 16 are portions having a function of supporting the temporal region of the occupant supported by the headrest HR. In the following description, among the left and right side support portions 16, the portions forming the headrest mounting portion 18 are connected to the left side support wall portion 22 and the right side support wall portion 24 and the rear end portions of the left and right side support portions 16. The support wall portion 26 to be used may be particularly referred to as a rear support wall portion 26. That is, the left side support wall portion 22 forms the outer peripheral left side portion of the pad base material 12, and the right side support wall portion 24 forms the outer peripheral right side portion of the pad base material 12.

ここで、左側支持壁部２２、右側支持壁部２４および後側支持壁部２６の外側面は、ヘッドレスト装着部１８の開口縁に近づくにつれて厚みが漸減する丸みを帯びた曲面形状に形成されて、ヘッドレスト装着部１８の開口縁の断面が鋭角状をなすよう形成されている。また、左側支持壁部２２および右側支持壁部２４の前縁部は、上端部から下方に向かうにつれて相互に離間する傾斜状に形成されて、ヘッドレスト装着部１８の前方開口が略台形状をなすよう形成されている。また左側支持壁部２２および右側支持壁部２４の上縁部は、前端部から後方に向かうにつれて僅かに近接するよう形成され、後側支持壁部２６の上縁部は、左右方向の中心で後方に僅かに突出する円弧状に形成されると共に、左側支持壁部２２、右側支持壁部２４の上縁部と後側支持壁部２６の上縁部との連設部が円弧状に湾曲して連続した湾曲形状に形成されている。 Here, the outer surfaces of the left side support wall portion 22, the right side support wall portion 24, and the rear side support wall portion 26 are formed in a rounded curved shape whose thickness gradually decreases as it approaches the opening edge of the headrest mounting portion 18. The cross section of the opening edge of the headrest mounting portion 18 is formed to form a sharp angle. Further, the front edge portions of the left side support wall portion 22 and the right side support wall portion 24 are formed in an inclined shape so as to be separated from each other from the upper end portion downward, and the front opening of the headrest mounting portion 18 has a substantially trapezoidal shape. Is formed. Further, the upper edge portions of the left side support wall portion 22 and the right side support wall portion 24 are formed so as to be slightly closer to each other from the front end portion toward the rear, and the upper edge portion of the rear side support wall portion 26 is at the center in the left-right direction. It is formed in an arc shape that slightly protrudes rearward, and the continuous portion between the upper edge portion of the left side support wall portion 22 and the right side support wall portion 24 and the upper edge portion of the rear side support wall portion 26 is curved in an arc shape. It is formed into a continuous curved shape.

補強部材３０は、図２、図３に示すように、パッド基材１２の外周上部の上縁に沿うようパッド基材１２の外表面側に埋設されており、ヘッドレスト装着部１８を補強してその変形を防止するよう構成される。この補強部材３０は、ヘッドレスト装着部１８の前方の開口縁(左側支持壁部２２の前端縁、右側支持壁部２４の前端縁)および上方の開口縁(左側支持壁部２２の上端縁、右側支持壁部２４および後側支持壁部２６の上端縁)に倣う湾曲形状に形成されており、ヘッドレスト装着部１８の外周縁を補強して座屈等の変形を防止するよう構成される。 As shown in FIGS. 2 and 3, the reinforcing member 30 is embedded on the outer surface side of the pad base material 12 so as to be along the upper edge of the upper periphery of the pad base material 12, and reinforces the headrest mounting portion 18. It is configured to prevent the deformation. The reinforcing member 30 has an opening edge in front of the headrest mounting portion 18 (front end edge of the left side support wall portion 22, front end edge of the right side support wall portion 24) and an upper opening edge (upper end edge of the left side support wall portion 22, right side). It is formed in a curved shape that follows the support wall portion 24 and the upper end edge of the rear support wall portion 26), and is configured to reinforce the outer peripheral edge of the headrest mounting portion 18 to prevent deformation such as buckling.

具体的に、本実施例の補強部材３０は、ヘッドレスト装着部１８の前端縁を補強する左側補強部３２および右側補強部３３と、ヘッドレスト装着部１８の上端縁を補強する上側補強部４４とを備えており、ヘッドレスト装着部１８の外周左右側部の前縁から外周上部の上縁に亘って延在する湾曲形状に形成されている。ここで、左側補強部３２は、パッド基材１２の外周左側部の前縁に倣うようヘッドレスト装着部１８における左側支持壁部２２の前縁に沿って延在し、右側補強部３３は、パッド基材１２の外周右側部の前縁に倣うようヘッドレスト装着部１８における右側支持壁部２４の前縁に沿って延在するよう形成されている。なお、この補強部材３０は、ポリプロピレン等の合成樹脂により一体成形された左右対称の部材として構成されている。 Specifically, the reinforcing member 30 of the present embodiment includes a left side reinforcing portion 32 and a right side reinforcing portion 33 that reinforce the front end edge of the headrest mounting portion 18, and an upper reinforcing portion 44 that reinforces the upper end edge of the headrest mounting portion 18. It is provided and is formed in a curved shape extending from the front edge of the left and right side portions of the outer periphery of the headrest mounting portion 18 to the upper edge of the upper part of the outer periphery. Here, the left side reinforcing portion 32 extends along the front edge of the left side support wall portion 22 in the headrest mounting portion 18 so as to follow the leading edge of the outer peripheral left side portion of the pad base material 12, and the right side reinforcing portion 33 extends along the front edge of the pad base material 12. It is formed so as to extend along the leading edge of the right support wall portion 24 in the headrest mounting portion 18 so as to follow the leading edge of the outer peripheral right portion of the base material 12. The reinforcing member 30 is configured as a symmetrical member integrally molded of a synthetic resin such as polypropylene.

左側補強部３２および右側補強部３３の夫々は、内側補強壁部３４と、内側補強壁部３４の外側に対向する外側補強壁部３６と、内側補強壁部３４および外側補強壁部３６の前端部を連結すると共に対応する左側支持壁部２２および右側支持壁部２４の前端縁に沿って延在する連設部３８とを備えている。そして、補強部材３０を埋設した状態で、左側補強部３２および右側補強部３３の各内側補強壁部３４が、対応する左側支持壁部２２および右側支持壁部２４においてヘッドレスト装着部１８に臨む壁面側に位置し、左側補強部３２および右側補強部３３の各外側補強壁部３６が、対応する左側支持壁部２２および右側支持壁部２４の外側面側に位置し、左側補強部３２および右側補強部３３の連設部３８が、対応する左側支持壁部２２および右側支持壁部２４の前端縁(外表面)に近接位置するよう構成されている。また、連設部３８の縁部は円弧状に湾曲するよう形成され、左側補強部３２および右側補強部３３の剛性を高めるよう構成してある。更に、内側補強壁部３４と外側補強壁部３６との間に、内側補強壁部３４および外側補強壁部３６を連結する支持部４０(図５参照)が設けられており、内側補強壁部３４および外側補強壁部３６が近接または離間するように撓み変形するのを防止するよう構成されている。これにより、左側補強部３２および右側補強部３３が埋設された左側支持壁部２２および右側支持壁部２４の夫々の厚み方向の剛性を高め、左側支持壁部２２および右側支持壁部２４の夫々を左右から圧縮するような力の作用に伴う変形を防止している。また、外側補強壁部３６の後端部は、外側に向けて円弧状に湾曲して折り返す第１の湾曲支持部４２が設けられており、外側補強壁部３６の剛性を高めて、左側支持壁部２２および右側支持壁部２４の形状安定性を高めるようにしてある。 The left side reinforcing portion 32 and the right side reinforcing portion 33 each have an inner reinforcing wall portion 34, an outer reinforcing wall portion 36 facing the outside of the inner reinforcing wall portion 34, and front ends of the inner reinforcing wall portion 34 and the outer reinforcing wall portion 36. It is provided with a continuous portion 38 that connects the portions and extends along the front end edge of the corresponding left support wall portion 22 and the right side support wall portion 24. Then, with the reinforcing member 30 embedded, each inner reinforcing wall portion 34 of the left side reinforcing portion 32 and the right side reinforcing portion 33 faces the headrest mounting portion 18 in the corresponding left side support wall portion 22 and right side support wall portion 24. The outer reinforcing wall portions 36 of the left side reinforcing portion 32 and the right side reinforcing portion 33 are located on the outer side of the corresponding left side support wall portion 22 and the right side support wall portion 24, and the left side reinforcing portion 32 and the right side are located. The continuous portion 38 of the reinforcing portion 33 is configured to be located close to the front end edge (outer surface) of the corresponding left side support wall portion 22 and the right side support wall portion 24. Further, the edge portion of the continuous portion 38 is formed so as to be curved in an arc shape, and is configured to increase the rigidity of the left side reinforcing portion 32 and the right side reinforcing portion 33. Further, a support portion 40 (see FIG. 5) for connecting the inner reinforcing wall portion 34 and the outer reinforcing wall portion 36 is provided between the inner reinforcing wall portion 34 and the outer reinforcing wall portion 36, and the inner reinforcing wall portion is provided. It is configured to prevent the 34 and the outer reinforcing wall portion 36 from bending and deforming so as to be close to each other or separated from each other. As a result, the rigidity in the thickness direction of the left side support wall portion 22 and the right side support wall portion 24 in which the left side reinforcement portion 32 and the right side reinforcement portion 33 are embedded is increased, and the left side support wall portion 22 and the right side support wall portion 24 are respectively. It prevents deformation due to the action of force that compresses from the left and right. Further, the rear end portion of the outer reinforcing wall portion 36 is provided with a first curved support portion 42 that is curved in an arc shape toward the outside and folded back, thereby increasing the rigidity of the outer reinforcing wall portion 36 to support the left side. The shape stability of the wall portion 22 and the right side support wall portion 24 is enhanced.

上側補強部４４は、左側支持壁部２２および右側支持壁部２４の上端縁に沿って延在する第１の上側補強壁部４６と、後側支持壁部２６の上端縁に沿って延在する第２の上側補強壁部４８とを備えて平面視でコ字状をなすよう形成されており、補強部材３０を埋設した状態で、第１の上側補強壁部４６および第２の上側補強壁部４８が対応する左側支持壁部２２、右側支持壁部２４および後側支持壁部２６の上端縁(外表面)に近接位置するよう構成されている。また、第１の上側補強壁部４６および第２の上側補強壁部４８の外側端部には、下側に向けて円弧状に湾曲して折り返す第２の湾曲支持部５０が設けられており、上側補強部４４の剛性を高めてその変形を防止するようになっている。 The upper reinforcing portion 44 extends along the upper end edge of the first upper reinforcing wall portion 46 extending along the upper end edge of the left side support wall portion 22 and the right side support wall portion 24, and the upper end edge of the rear side support wall portion 26. The second upper reinforcing wall portion 48 is provided to form a U-shape in a plan view, and the first upper reinforcing wall portion 46 and the second upper reinforcing wall portion are reinforced in a state where the reinforcing member 30 is embedded. The wall portion 48 is configured to be located close to the upper end edge (outer surface) of the corresponding left side support wall portion 22, the right side support wall portion 24, and the rear side support wall portion 26. Further, at the outer end portions of the first upper reinforcing wall portion 46 and the second upper reinforcing wall portion 48, a second curved support portion 50 that is curved downward in an arc shape and folded back is provided. , The rigidity of the upper reinforcing portion 44 is increased to prevent its deformation.

また、補強部材３０は、図４、図５に示すように、左側補強部３２および右側補強部３３の各内側補強壁部３４の後端部に連設する補強支持部５２が左右方向に延在するよう設けられている。この補強支持部５２には、前方へ突出する突出部５６が左右方向に離間する複数箇所(実施例では３箇所)に形成されると共に、各突出部５６の突出端部に前後に貫通する嵌合孔５６ａが開口するよう設けられている。本実施例では、補強支持部５２における左右の中間および左右の両端部に位置するよう突出部５６を夫々設けてある。そして、補強部材３０をパッド基材１２に埋設した状態で、この突出部５６の嵌合孔５６ａがヘッドレスト装着部１８の下部前面側に露出するよう構成されており、シートを装飾する飾り部材Ｋ(図６参照)に設けた係合部Ｋａを嵌合孔５６ａに前側から差し込んで係合させることにより、飾り部材Ｋをパッド基材１２に取り付け得るようになっている。なお、飾り部材Ｋは、突出部５６の嵌合孔５６ａに合わせて形成されたシートカバーＳＣの開口部を挿通した状態で係合部Ｋａを差し込んで係合されるものである。なお、各突出部５６は、中空状に形成されると共に後方に開口するよう形成されており、突出部５６の後方開口部５６ｂをシール材５７により塞ぐよう構成されて、突出部５６の後方の開口から突出部５６の内部に発泡原料が侵入しないよう構成されている。 Further, as shown in FIGS. 4 and 5, in the reinforcing member 30, the reinforcing support portion 52 continuously provided at the rear end portion of each inner reinforcing wall portion 34 of the left side reinforcing portion 32 and the right side reinforcing portion 33 extends in the left-right direction. It is provided to be there. In the reinforcing support portion 52, the protruding portions 56 projecting forward are formed at a plurality of locations (three locations in the embodiment) separated in the left-right direction, and are fitted to the protruding end portions of the protruding portions 56 in the front-rear direction. The joint hole 56a is provided so as to open. In this embodiment, protrusions 56 are provided so as to be located in the middle of the left and right sides of the reinforcing support portion 52 and at both ends of the left and right sides. Then, in a state where the reinforcing member 30 is embedded in the pad base material 12, the fitting hole 56a of the protruding portion 56 is configured to be exposed on the lower front side of the headrest mounting portion 18, and the decorative member K for decorating the sheet is configured. The decorative member K can be attached to the pad base material 12 by inserting the engaging portion Ka provided in (see FIG. 6) into the fitting hole 56a from the front side and engaging the engaging portion Ka. The decorative member K is engaged by inserting the engaging portion Ka with the opening of the seat cover SC formed in accordance with the fitting hole 56a of the protruding portion 56 inserted. Each protrusion 56 is formed in a hollow shape and is formed so as to open rearward, and is configured to close the rear opening 56b of the protrusion 56 with a sealing material 57 so as to be behind the protrusion 56. It is configured to prevent the foaming material from entering the inside of the protrusion 56 from the opening.

また、補強支持部５２の後面側には、左右方向に離間する複数箇所(実施例では６箇所)に、後方へ突出する支持片５８,６０が形成されている。本実施例では、補強支持部５２の後面側において、各突出部５６を挟む左右に隣接位置するよう支持片５８,６０を夫々設けてある。すなわち、左右の中間に位置する突出部５６に対応して一対の第１の支持片５８が設けられ、左右の両端部に位置する突出部５６の夫々に対応して一対の第２の支持片６０が設けられている。各支持片５８,６０は、シートパッド１０を支持するシートフレームＳＦの前側に位置するよう設けられており、補強部材３０(補強支持部５２)が後方へ撓むよう変形した際に、パッド基材１２を挟んでシートフレームＳＦにより各支持片５８,６０が支持されることで、撓み変形を抑制して補強部材３０の破損を防止するようになっている。 Further, on the rear surface side of the reinforcing support portion 52, support pieces 58, 60 projecting rearward are formed at a plurality of locations (six locations in the embodiment) separated in the left-right direction. In this embodiment, the support pieces 58 and 60 are provided on the rear surface side of the reinforcing support portion 52 so as to be adjacent to each other on the left and right sides of the protruding portions 56, respectively. That is, a pair of first support pieces 58 are provided corresponding to the protrusions 56 located in the middle of the left and right, and a pair of second support pieces are provided corresponding to the protrusions 56 located at both left and right ends. 60 is provided. Each of the support pieces 58 and 60 is provided so as to be located on the front side of the seat frame SF that supports the seat pad 10, and when the reinforcing member 30 (reinforcing support portion 52) is deformed so as to bend backward, the pad base material By supporting the support pieces 58 and 60 by the seat frame SF sandwiching the 12, the bending deformation is suppressed and the reinforcing member 30 is prevented from being damaged.

ここで、第１の支持片５８は、補強支持部５２の上下方向に延在する板状に形成されると共に後端部に円弧状凹部５８ａが形成されている。ここで、円弧状凹部５８ａは、シートフレームＳＦを構成する金属管の管径に合わせた曲率で形成されており、乗員がシートパッド１０に凭れる様な姿勢を採った場合などに補強支持部５２の中央部が後方へ撓むことで、パッド基材１２を挟んでシートフレームＳＦが第１の支持片５８の円弧状凹部５８ａに噛み合うようになっている。また、第２の支持片６０は、補強支持部５２の上下方向に延在する板状に形成されると共に、その後端部が下方へ向かうにつれて後方へ傾斜する傾斜状に形成されており、パッド基材１２を挟んで第２の支持片６０の傾斜部がシートフレームＳＦにより支持されるようになっている。 Here, the first support piece 58 is formed in a plate shape extending in the vertical direction of the reinforcing support portion 52, and an arc-shaped recess 58a is formed at the rear end portion. Here, the arcuate recess 58a is formed with a curvature matching the diameter of the metal pipe constituting the seat frame SF, and is a reinforcing support portion when the occupant takes a posture of leaning against the seat pad 10. Since the central portion of the 52 bends backward, the seat frame SF meshes with the arcuate recess 58a of the first support piece 58 with the pad base material 12 interposed therebetween. Further, the second support piece 60 is formed in a plate shape extending in the vertical direction of the reinforcing support portion 52, and is formed in an inclined shape in which the rear end portion is inclined backward as the rear end portion is directed downward. The inclined portion of the second support piece 60 with the base material 12 interposed therebetween is supported by the seat frame SF.

次に、前述したシートパッド１０の製造方法に関して説明する。本発明に係るシートパッド１０は、型閉め状態および型開き状態に変位可能な複数の型(分割型)により構成された成形型７０に画成されるキャビティに補強部材３０を配置した状態で、ポリウレタン樹脂等の発泡原料を発泡硬化させることにより、発泡体からなるパッド基材１２に補強部材３０が埋設されるよう形成される。この成形型７０は、図７に示すように、シートパッド１０において乗員の背中を支持する支持面(前面)を成形する下型７２と、下型７２に対して回動可能に支持されてシートパッド１０の裏面(後面)を成形する上型８１,８２とを備えており、上型８１,８２に接続されたシリンダ等の駆動手段(図示せず)を駆動することで、下型７２に対して上型８１,８２が開いた型開き状態と、下型７２に対して上型８１,８２が閉じた型閉め状態とに変位し得るよう構成されている。そして、下型７２に対して上型８１,８２を閉じた型閉め状態において、シートパッド１０の外形形状と同じ空間形状をなすキャビティが成形型７０の内部に画成されるようになっている。 Next, the method for manufacturing the above-mentioned seat pad 10 will be described. The seat pad 10 according to the present invention has a reinforcing member 30 arranged in a cavity defined in a molding die 70 composed of a plurality of molds (divided molds) that can be displaced to a mold closed state and a mold open state. By foaming and curing a foaming raw material such as polyurethane resin, the reinforcing member 30 is formed so as to be embedded in the pad base material 12 made of foam. As shown in FIG. 7, the molding die 70 has a lower die 72 that forms a support surface (front surface) that supports the back of the occupant in the seat pad 10, and a seat that is rotatably supported by the lower die 72. It is equipped with upper dies 81, 82 for forming the back surface (rear surface) of the pad 10, and by driving a driving means (not shown) such as a cylinder connected to the upper dies 81, 82, the lower die 72 can be formed. On the other hand, the upper mold 81, 82 is configured to be open and the upper mold 81, 82 is closed with respect to the lower mold 72. Then, in the closed state in which the upper molds 81 and 82 are closed with respect to the lower mold 72, a cavity having the same spatial shape as the outer shape of the seat pad 10 is defined inside the molding mold 70. ..

ここで、下型７２は、シートパッド１０(パッド基材１２)における本体部１３の前面(乗員の背中を支持する支持面)を成形する本体部成形面(第１の成形面)７３の一端側(図７における左端側)に、ヘッドレスト装着部１８の底面を形成する底部成形面７４が連なるよう形成されると共に、底部成形面７４の上端部に、ヘッドレスト装着部１８の後側支持壁部２６の前面を形成する後側支持壁部成形面(第２の成形面)７５が連なるよう形成されている。また、下型７２には、図１０に示すように、ヘッドレスト装着部１８の左側支持壁部２２を成形する左側支持壁部成形面(第３の成形面)７６が後側支持壁部成形面７５の一側部(図１０では右側の側部)および底部成形面７４に連なるよう形成されると共に、ヘッドレスト装着部１８の右側支持壁部２４を成形する右側支持壁部成形面(第４の成形面)７７が後側支持壁部成形面７５の他側部(図１０では左側の側部)および底部成形面７４に連なるよう形成されている。 Here, the lower mold 72 is one end of a main body portion molded surface (first molded surface) 73 that forms the front surface (support surface that supports the back of the occupant) of the main body portion 13 in the seat pad 10 (pad base material 12). The bottom molding surface 74 forming the bottom surface of the headrest mounting portion 18 is formed to be continuous on the side (left end side in FIG. 7), and the rear support wall portion of the headrest mounting portion 18 is formed on the upper end portion of the bottom molding surface 74. The rear support wall portion forming surface (second forming surface) 75 forming the front surface of the 26 is formed so as to be continuous. Further, as shown in FIG. 10, the lower mold 72 has a left support wall portion molding surface (third molding surface) 76 for molding the left support wall portion 22 of the headrest mounting portion 18 as a rear support wall portion molding surface. A right support wall forming surface (fourth) that is formed so as to be connected to one side of 75 (the right side in FIG. 10) and the bottom forming surface 74 and forms the right support wall 24 of the headrest mounting portion 18. The molded surface) 77 is formed so as to be connected to the other side portion (the left side portion in FIG. 10) of the rear support wall portion molded surface 75 and the bottom molded surface 74.

また、図７、図９に示すように、下型７２の本体部成形面７３には、底部成形面７４との連設位置の近傍に上方へ突出するよう嵌合突部７８が設けられている。この嵌合突部７８は、本体部成形面７３と底部成形面７４との連設縁部の延在方向に離間する複数箇所(この実施例では３箇所)に設けられている。この複数の嵌合突部７８は、補強部材３０に形成した各突出部５６の嵌合孔５６ａに対応するよう設けられており、型開き状態としたもとで、補強部材３０に形成した各突出部５６の嵌合孔５６ａを、各嵌合突部７８に対して上方から嵌合させ得るようになっている。また、各嵌合突部７８は、図９、図１０に示すように、突出端側に向けて先細りとなる形状に形成されており、補強部材３０の各嵌合孔５６ａを対応する各嵌合突部７８に容易に嵌合させ得るよう構成されている。すなわち、補強部材３０の各嵌合孔５６ａを対応する各嵌合突部７８に嵌合することで、後側支持壁部成形面７５において後側支持壁部２６の上端部を成形する縁部に沿って補強部材３０の第２の上側補強壁部４８が延在し(図９参照)、左側支持壁部成形面７６の底部に沿って補強部材３０における左側補強部３２の連設部３８が延在すると共に、右側支持壁部成形面７７の底部に沿って補強部材３０における右側補強部３３の連設部３８が延在する位置で補強部材３０が支持されるようになっている(図１０参照)。また、図示を省略するが、同様に補強部材３０の各嵌合孔５６ａを対応する各嵌合突部７８に嵌合することで、左側支持壁部成形面７６において左側支持壁部２２の上端部を成形する縁部に沿って補強部材３０の左側の第１の上側補強壁部４６が延在し、右側支持壁部２４成形面において右側支持壁部２４の上端部を成形する縁部に沿って補強部材３０の右側の第１の上側補強壁部４６が延在する位置で補強部材３０が支持される。 Further, as shown in FIGS. 7 and 9, the main body molding surface 73 of the lower mold 72 is provided with a fitting protrusion 78 so as to project upward in the vicinity of the position where the lower mold 72 is connected to the bottom molding surface 74. There is. The fitting protrusions 78 are provided at a plurality of locations (three locations in this embodiment) that are separated from each other in the extending direction of the continuous edge portion between the main body portion molded surface 73 and the bottom molded surface 74. The plurality of fitting protrusions 78 are provided so as to correspond to the fitting holes 56a of the protruding portions 56 formed in the reinforcing member 30, and are formed in the reinforcing member 30 in the open state. The fitting hole 56a of the protrusion 56 can be fitted to each fitting protrusion 78 from above. Further, as shown in FIGS. 9 and 10, each fitting protrusion 78 is formed in a shape that tapers toward the protruding end side, and each fitting hole 56a of the reinforcing member 30 corresponds to each fitting. It is configured so that it can be easily fitted to the abutment portion 78. That is, by fitting each fitting hole 56a of the reinforcing member 30 to each corresponding fitting protrusion 78, an edge portion for forming the upper end portion of the rear support wall portion 26 on the rear support wall portion forming surface 75. A second upper reinforcing wall portion 48 of the reinforcing member 30 extends along the line (see FIG. 9), and a continuous portion 38 of the left side reinforcing portion 32 in the reinforcing member 30 along the bottom portion of the left side support wall portion molded surface 76. Is extended, and the reinforcing member 30 is supported at a position where the continuous portion 38 of the right side reinforcing portion 33 in the reinforcing member 30 extends along the bottom of the right side support wall portion forming surface 77 (. See FIG. 10). Further, although not shown, by fitting each fitting hole 56a of the reinforcing member 30 to each corresponding fitting protrusion 78, the upper end of the left support wall portion 22 on the left support wall portion forming surface 76 is similarly formed. The first upper reinforcing wall portion 46 on the left side of the reinforcing member 30 extends along the edge portion for forming the portion, and the upper end portion of the right side support wall portion 24 is formed on the molding surface of the right side support wall portion 24. The reinforcing member 30 is supported at a position extending along the first upper reinforcing wall portion 46 on the right side of the reinforcing member 30.

また、上型８１,８２は、図７に示すように、下型７２に対して回動可能に支持された第１の上型８１と、第１の上型８１に支持されて第１の上型８１と下型７２との間に位置する第２の上型８２とを備えるよう構成されている。この第１の上型８１は、ヘッドレスト装着部１８の後側支持壁部２６の後面を成形する第１の上成形面８４ａを有する第１成形部材８４と、シートパッド１０(パッド基材１２)の下端部の後面を成形する第２の上成形面８５ａを有する第２成形部材８５とを連結部材８６で連結して構成されており、第１の上成形面８４ａおよび第２の上成形面８５ａの間を第２の上型８２が繋ぐ成形位置と、第１の上成形面８４ａおよび第２の上成形面８５ａから第２の上型８２が離間した分離位置とに変位可能にし得るよう第２の上型８２が連結部材８６に支持されている。すなわち、第２の上型８２が成形位置に位置することで、第１の上型８１および第２の上型８２によりシートパッド１０(パッド基材１２)の後面側の形状を成形するようになっている。ここで、第２の上型８２を連結部材８６に支持する構成としては、図７、図８に示すように、第２の上型８２の上面側に形成したスライド溝８７に、連結部材８６に固定されたガイドバー８８の端部を挿入することで、第１の上型８１に対して第２の上型８２が成形位置および分離位置に移動可能に支持されると共に、連結部材８６に設けた係止部８９に対して分離位置で係合する係合部材９０を第２の上型８２に設けることで構成されている。なお、第２の上型８２を連結部材８６に支持する構成は、このような構成に限られるものではなく、適宜に形成することができる。 Further, as shown in FIG. 7, the upper molds 81 and 82 have a first upper mold 81 rotatably supported with respect to the lower mold 72 and a first upper mold 81 supported by the first upper mold 81. It is configured to include a second upper die 82 located between the upper die 81 and the lower die 72. The first upper mold 81 has a first molding member 84 having a first upper molding surface 84a for molding the rear surface of the rear support wall portion 26 of the headrest mounting portion 18, and a seat pad 10 (pad base material 12). A second upper forming member 85 having a second upper forming surface 85a for forming the rear surface of the lower end portion of the above portion is connected by a connecting member 86, and the first upper forming surface 84a and the second upper forming surface are connected. The molding position where the second upper mold 82 is connected between the 85a and the separation position where the first upper molding surface 84a and the second upper mold 82 are separated from the second upper molding surface 85a can be displaced. The second upper mold 82 is supported by the connecting member 86. That is, when the second upper mold 82 is located at the molding position, the shape of the rear surface side of the seat pad 10 (pad base material 12) is molded by the first upper mold 81 and the second upper mold 82. It has become. Here, as a configuration in which the second upper die 82 is supported by the connecting member 86, as shown in FIGS. 7 and 8, the connecting member 86 is formed in the slide groove 87 formed on the upper surface side of the second upper die 82. By inserting the end portion of the guide bar 88 fixed to the first upper mold 81, the second upper mold 82 is movably supported at the molding position and the separation position with respect to the first upper mold 81, and is also supported by the connecting member 86. The second upper die 82 is provided with an engaging member 90 that engages with the provided locking portion 89 at a separated position. The configuration in which the second upper mold 82 is supported by the connecting member 86 is not limited to such a configuration, and can be appropriately formed.

また、第２の上型８２には、図７～図９に示すように、型閉めした際に、下型７２の嵌合突部７８に嵌合させた補強部材３０に対して上方から当接する係合突部９２が設けられている。すなわち、下型７２に対して第２の上型８２を型閉めした際に、第２の上型８２に設けた係合突部９２が補強部材３０に当接して、下型７２と係合突部９２とにより補強部材３０を挟持するようになっている。そして、補強部材３０を挟持した状態において、補強部材３０における前述した左側補強部３２の連設部３８、右側補強部３３の連設部３８、第１の上側補強壁部４６、第２の上側補強壁部４８の夫々が、対応する各成形面７６,７７,７５から僅かに離間した姿勢で補強部材３０が保持されるようになっている。 Further, as shown in FIGS. 7 to 9, the second upper mold 82 is in contact with the reinforcing member 30 fitted to the fitting protrusion 78 of the lower mold 72 from above when the mold is closed. An engaging protrusion 92 in contact is provided. That is, when the second upper mold 82 is closed with respect to the lower mold 72, the engaging protrusion 92 provided on the second upper mold 82 abuts on the reinforcing member 30 and engages with the lower mold 72. The reinforcing member 30 is sandwiched between the protrusions 92 and the protrusions 92. Then, in a state where the reinforcing member 30 is sandwiched, the continuous portion 38 of the left side reinforcing portion 32, the continuous portion 38 of the right side reinforcing portion 33, the first upper reinforcing wall portion 46, and the second upper side of the reinforcing member 30 are sandwiched. The reinforcing member 30 is held in a posture in which each of the reinforcing wall portions 48 is slightly separated from each of the corresponding molding surfaces 76,77,75.

ここで、係合突部９２は、図９、図１０に示すように、嵌合突部７８を嵌合孔５６ａに嵌合させた姿勢の補強部材３０の補強支持部５２に対して上方から当接する(すなわち補強支持部５２の後面側に当接する)ようになっている。この係合突部９２は、左右の中間に位置する突出部５６を挟む左右に隣接した位置で当接するよう第１の支持片５８の近接位置に設けられると共に、左右の両端部に位置する突出部５６に対して、中間に位置する突出部５６側に隣接した位置で当接するよう第２の支持片６０の近接位置に設けられている。ポリウレタン樹脂等の発泡原料をキャビティ内に注入すると、下型７２の後側支持壁部成形面７５と、補強部材３０の第２の上側補強壁部４８との間に発泡原料が入り込み、発泡硬化する際の発泡圧により第２の上側補強壁部４８が押し上げられ、配置された補強部材３０の位置がずれる力が作用する。このとき、補強部材３０の補強支持部５２に対して係合突部９２が当接することで、発泡原料の発泡圧に伴う成形型７０の上下方向に対する補強部材３０のずれを規制するようになっている。すなわち、補強部材３０に設けた各突出部５６に近接した位置で係合突部９２を補強支持部５２に当接させることで、各突出部５６の突出端部が下型７２から浮き上がらないよう固化的に押さえることができる。 Here, as shown in FIGS. 9 and 10, the engaging protrusion 92 is viewed from above with respect to the reinforcing support portion 52 of the reinforcing member 30 in a posture in which the fitting protrusion 78 is fitted into the fitting hole 56a. It is designed to abut (that is, to abut on the rear surface side of the reinforcing support portion 52). The engaging protrusion 92 is provided at a position close to the first support piece 58 so as to abut at positions adjacent to the left and right sandwiching the protrusion 56 located between the left and right, and the protrusions located at both left and right ends. It is provided at a position close to the second support piece 60 so as to abut on the portion 56 at a position adjacent to the protruding portion 56 side located in the middle. When a foamed raw material such as polyurethane resin is injected into the cavity, the foamed raw material enters between the rear support wall portion molded surface 75 of the lower mold 72 and the second upper reinforcing wall portion 48 of the reinforcing member 30, and is foamed and cured. The second upper reinforcing wall portion 48 is pushed up by the foaming pressure at the time of the operation, and a force for shifting the position of the arranged reinforcing member 30 acts. At this time, the engaging protrusion 92 abuts on the reinforcing support portion 52 of the reinforcing member 30 to regulate the displacement of the reinforcing member 30 in the vertical direction of the molding die 70 due to the foaming pressure of the foaming raw material. ing. That is, by bringing the engaging protrusion 92 into contact with the reinforcing support portion 52 at a position close to each protruding portion 56 provided on the reinforcing member 30, the protruding end portion of each protruding portion 56 is prevented from rising from the lower mold 72. It can be solidified.

また、図９、図１０に示すように、第１の上型８１には、後側支持壁部成形面７５と対向する位置に、型閉め状態で後側支持壁部成形面７５側へ向けて突出する位置規制突部９４が設けられている。この位置規制突部９４は、成形型７０を型閉めした状態で、後側支持壁部成形面７５の縁部に沿って延在する補強部材３０の第２の上側補強壁部４８に対して、本体部成形面７３の他端側の縁部に当接するよう構成されている。キャビティ内に注入された発泡原料の発泡圧により、第２の上側補強壁部４８が本体部成形面７３の他端側に押されても、補強部材３０の第２の上側補強壁部４８に対して位置規制突部９４が当接することで、発泡原料の発泡圧に伴う成形型７０の一端側および他端側方向に対する補強部材３０のずれを規制するようになっている。なお、図４において、係合突部９２が補強部材３０(補強支持部５２)に当接する位置の前面側に対応する位置、および第２の上側補強壁部４８に対して位置規制突部９４が当接する位置の夫々を、二点鎖線で示している。 Further, as shown in FIGS. 9 and 10, the first upper die 81 faces the rear support wall forming surface 75 at a position facing the rear support wall forming surface 75 in the closed state. A position-regulating protrusion 94 is provided so as to project. The position restricting protrusion 94 is provided with respect to the second upper reinforcing wall portion 48 of the reinforcing member 30 extending along the edge portion of the rear support wall portion molding surface 75 in a state where the molding die 70 is closed. , It is configured to abut on the other end side edge of the main body molding surface 73. Even if the second upper reinforcing wall portion 48 is pushed to the other end side of the main body molding surface 73 by the foaming pressure of the foaming raw material injected into the cavity, the second upper reinforcing wall portion 48 of the reinforcing member 30 is pressed. On the other hand, when the position-regulating protrusion 94 comes into contact with the foaming material, the displacement of the reinforcing member 30 with respect to one end side and the other end side of the molding die 70 due to the foaming pressure of the foaming raw material is regulated. In FIG. 4, the position corresponding to the front side of the position where the engaging protrusion 92 abuts on the reinforcing member 30 (reinforcing support portion 52), and the position restricting protrusion 94 with respect to the second upper reinforcing wall portion 48. Each of the positions where is abutted is indicated by a two-dot chain line.

次に、前述のように構成した成形型７０を使用したシートパッドの製造手順に関して説明する。下型７２に対して上型８１,８２を型開き状態としたもとで、補強部材３０の各突出部５６に設けた嵌合孔５６ａを、下型７２に設けた対応する嵌合突部７８に嵌合させて、突出部５６の突出端部を下型７２の本体部成形面７３に当接させるよう補強部材３０を設置する(図７参照)。これにより、補強部材３０の左側補強部３２の連設部３８、右側補強部３３の連設部３８、第１の上側補強壁部４６、第２の上側補強壁部４８の夫々が対応する各成形面７６,７７,７５に沿って延在する所定位置に補強部材３０が位置決めされる。 Next, a procedure for manufacturing a seat pad using the molding die 70 configured as described above will be described. With the upper molds 81 and 82 in the mold open state with respect to the lower mold 72, the fitting holes 56a provided in each protruding portion 56 of the reinforcing member 30 are provided in the corresponding fitting protrusions in the lower mold 72. A reinforcing member 30 is installed so as to be fitted to 78 so that the protruding end portion of the protruding portion 56 is brought into contact with the main body forming surface 73 of the lower mold 72 (see FIG. 7). As a result, the continuous portion 38 of the left side reinforcing portion 32 of the reinforcing member 30, the continuous portion 38 of the right side reinforcing portion 33, the first upper reinforcing wall portion 46, and the second upper reinforcing wall portion 48 correspond to each corresponding. The reinforcing member 30 is positioned at a predetermined position extending along the molding surface 76, 77, 75.

次いで、型開き状態のまま下型７２により形成されるキャビティ内に所定量の発泡原料を注入し、下型７２に対して上型８１,８２を型閉じする。このとき、図９、図１０に示すように、第２の上型８２に設けた係合突部９２が下型７２に設置した状態の補強部材３０を下型７２の方向に押し付けるように当接して、嵌合突部７８を形成した下型７２と係合突部９２とにより補強部材３０を挟持すると共に、第１の上型８１に設けた位置規制突部９４が補強部材３０の第２の上側補強壁部４８に対して、本体部成形面７３の他端側の縁部に当接し、この状態で発泡原料が発泡することによりパッド基材１２を形成する。その後、下型７２に対して上型８１および上型８２を型開き状態に変位させてパッド基材１２を脱型することにより、湾曲した外周縁に沿うよう外表面側に補強部材３０が埋設された状態で補強部材３０の嵌合孔５６ａが外表面で開口するシートパッド１０を得ることができる。 Next, a predetermined amount of foaming raw material is injected into the cavity formed by the lower mold 72 while the mold is open, and the upper molds 81 and 82 are closed with respect to the lower mold 72. At this time, as shown in FIGS. 9 and 10, the engaging protrusion 92 provided on the second upper mold 82 presses the reinforcing member 30 installed on the lower mold 72 toward the lower mold 72. The reinforcing member 30 is sandwiched between the lower mold 72 forming the fitting protrusion 78 and the engaging protrusion 92, and the position-regulating protrusion 94 provided on the first upper mold 81 is the first of the reinforcing member 30. The pad base material 12 is formed by abutting the upper reinforcing wall portion 48 of 2 against the edge portion on the other end side of the molding surface 73 of the main body portion and foaming the foaming raw material in this state. After that, the upper mold 81 and the upper mold 82 are displaced with respect to the lower mold 72 to remove the pad base material 12, and the reinforcing member 30 is embedded on the outer surface side along the curved outer peripheral edge. It is possible to obtain a seat pad 10 in which the fitting hole 56a of the reinforcing member 30 opens on the outer surface in this state.

このように、補強部材３０の嵌合孔５６ａを下型７２に設けた嵌合突部７８に嵌合して、嵌合突部７８を形成した下型７２と別の分割型(第２の上型８２)に設けた係合突部９２とにより補強部材３０を挟持することで、成形型７０のキャビティ内に位置ずれすることなく補強部材３０を正確に位置決めすることができ、シートパッド１０において変形防止が求められる部位に補強部材３０を配置することができる。また、補強部材３０の嵌合孔５６ａが下型７２の嵌合突部７８に嵌合することで、発泡原料が発泡硬化する際の発泡圧により補強部材３０が位置ずれするのを防止できる。 In this way, the fitting hole 56a of the reinforcing member 30 is fitted into the fitting protrusion 78 provided in the lower mold 72, and the fitting protrusion 78 is formed. By sandwiching the reinforcing member 30 with the engaging protrusion 92 provided on the upper mold 82), the reinforcing member 30 can be accurately positioned without being displaced in the cavity of the molding mold 70, and the seat pad 10 can be positioned. The reinforcing member 30 can be arranged at a portion where deformation prevention is required. Further, by fitting the fitting hole 56a of the reinforcing member 30 into the fitting protrusion 78 of the lower mold 72, it is possible to prevent the reinforcing member 30 from being displaced due to the foaming pressure when the foamed raw material is foamed and cured.

また、補強部材３０を挟持することで、補強部材３０において嵌合孔５６ａを設けた突出部５６の突出端部を下型７２に密着させることができるから、嵌合孔５６ａの内部に発泡原料が侵入するのを防ぐことができ、発泡原料を発泡させることで形成される発泡体により嵌合孔５６ａが塞がれたり、突出部５６の内部に発泡体が浸入するのを防止できる。そして、嵌合突部７８を嵌合孔５６ａに嵌合することにより、嵌合孔５６ａをシートパッド１０の外表面で開口させることができるから、シートパッド１０を装飾する飾り部材Ｋを取付ける際に、発泡体により嵌合孔５６ａが塞がれたり、突出部５６の内部に侵入した発泡体を取り除く等の作業が不要となり、飾り部材Ｋを容易に取付けることができる。 Further, by sandwiching the reinforcing member 30, the protruding end portion of the protruding portion 56 provided with the fitting hole 56a in the reinforcing member 30 can be brought into close contact with the lower mold 72, so that the foaming material can be brought into the inside of the fitting hole 56a. Can be prevented from invading, and the fitting hole 56a can be prevented from being blocked by the foam formed by foaming the foaming raw material, and the foam can be prevented from entering the inside of the protrusion 56. Then, by fitting the fitting protrusion 78 into the fitting hole 56a, the fitting hole 56a can be opened on the outer surface of the seat pad 10, so that when the decorative member K for decorating the seat pad 10 is attached. In addition, the fitting hole 56a is closed by the foam, and the work of removing the foam that has penetrated into the protrusion 56 becomes unnecessary, and the decorative member K can be easily attached.

更に、嵌合突部７８が嵌合孔５６ａに嵌合する嵌合位置から偏倚した位置で延在する補強部材３０(補強支持部５２)に対して、係合突部９２を当接させることで、発泡原料を発泡した際の発泡圧により補強部材３０がずれるのを防ぐことができ、パッド基材１２において変形防止が求められる部位に補強部材３０を正確に配置することができる。また、補強部材３０がずれるのを防ぐことで、発泡圧により補強部材３０が歪められた状態でパッド基材１２に埋設されるのを防止できるから、成形後に補強部材３０の復元力によりパッド基材１２が変形するのを防止できる利点がある。また、補強部材３０のずれを防ぐことで、突出部５６の突出端部が下型７２の本体部成形面７３からずれるのを防止でき、発泡体により嵌合孔５６ａが塞がれたり、突出部５６の内部に発泡体が浸入するのをより効果的に防止できる。 Further, the engaging protrusion 92 is brought into contact with the reinforcing member 30 (reinforcing support portion 52) extending at a position deviated from the fitting position where the fitting protrusion 78 fits into the fitting hole 56a. Therefore, it is possible to prevent the reinforcing member 30 from shifting due to the foaming pressure when the foaming raw material is foamed, and it is possible to accurately arrange the reinforcing member 30 at a portion of the pad base material 12 where deformation prevention is required. Further, by preventing the reinforcing member 30 from shifting, it is possible to prevent the reinforcing member 30 from being embedded in the pad base material 12 in a state of being distorted by the foaming pressure. There is an advantage that the material 12 can be prevented from being deformed. Further, by preventing the reinforcing member 30 from shifting, it is possible to prevent the protruding end of the protruding portion 56 from shifting from the molding surface 73 of the main body of the lower mold 72, and the fitting hole 56a is blocked or protruded by the foam. It is possible to more effectively prevent the foam from entering the inside of the portion 56.

また、前述した本発明に係る製造方法により製造された車両用のシートパッド１０は、シートパッド１０の外周縁に沿うよう補強部材３０を外表面側に埋設することにより、パッド基材１２の外周縁が補強部材３０により支持され、カバーリング時等にパッド基材１２の外周縁が変形するのを効果的に防止できる。特に、パッド基材１２の外周左右側部の前縁から外周上部の上縁に亘って延在する形状に補強部材３０を形成することで、パッド基材１２の上部側の剛性を効果的に高めることができる。また、パッド基材１２を高密度の発泡体により形成することなくパッド基材１２の外周縁に必要な剛性を確保して変形を防止できる。更に、補強部材３０がパッド基材１２に埋設されていることにより、パッド基材１２の変形を防止するための部材をパッド基材１２に後工程で取り付ける等の工程が必要なく、作業効率が格段に高くなると共に一定の品質を維持することができる。 Further, the seat pad 10 for a vehicle manufactured by the manufacturing method according to the present invention described above is outside the pad base material 12 by embedding a reinforcing member 30 on the outer surface side along the outer peripheral edge of the seat pad 10. The peripheral edge is supported by the reinforcing member 30, and it is possible to effectively prevent the outer peripheral edge of the pad base material 12 from being deformed during covering or the like. In particular, by forming the reinforcing member 30 in a shape extending from the front edge of the left and right sides of the outer circumference of the pad base material 12 to the upper edge of the upper part of the outer circumference, the rigidity of the upper side of the pad base material 12 is effectively increased. Can be enhanced. Further, it is possible to secure the required rigidity on the outer peripheral edge of the pad base material 12 and prevent deformation without forming the pad base material 12 with a high-density foam. Further, since the reinforcing member 30 is embedded in the pad base material 12, there is no need for a step of attaching a member for preventing deformation of the pad base material 12 to the pad base material 12 in a later step, and the work efficiency is improved. It can be significantly higher and maintain a certain level of quality.

また、パッド基材１２の外表面側に位置するよう補強部材３０を埋設することで、パッド基材１２の肉厚を薄くしても剛性を確保して形状安定性を維持することができる。すなわち、本発明に係るシートパッド１０のように、ヘッドレストＨＲとのデザインの一体性を実現するためにヘッドレスト装着部１８の薄肉状部分を形成した場合でも、ヘッドレスト装着部１８の前方の開口縁および上方の開口縁に倣う形状に形成した補強部材３０を埋設することで、ヘッドレスト装着部１８の剛性を確保することができ、ヘッドレスト装着部１８の形状保持性を高めつつシートパッド１０のデザインを多様化することが容易に実現可能となる。 Further, by embedding the reinforcing member 30 so as to be located on the outer surface side of the pad base material 12, rigidity can be ensured and shape stability can be maintained even if the wall thickness of the pad base material 12 is reduced. That is, even when a thin-walled portion of the headrest mounting portion 18 is formed in order to realize design integrity with the headrest HR as in the seat pad 10 according to the present invention, the opening edge in front of the headrest mounting portion 18 and By embedding the reinforcing member 30 formed in a shape that imitates the upper opening edge, the rigidity of the headrest mounting portion 18 can be ensured, and the design of the seat pad 10 is diversified while improving the shape retention of the headrest mounting portion 18. It can be easily realized.

また、補強部材３０の左側補強部３２および右側補強部３３を補強支持部５２で連結するようにしたことで、補強部材３０のねじれ剛性を高めることができる。更に、シートパッド１０を支持するシートフレームＳＦの前側に対応する位置に補強部材３０(補強支持部５２)を埋設すると共に、補強部材３０(補強支持部５２)に支持片５８,６０を形成して、補強部材３０が後方へ撓むよう変形した際にパッド基材１２を介してシートフレームＳＦで各支持片５８,６０が支持されるようにすることにより、補強部材３０の変形を抑制して損傷等を防止することができるから、補強部材３０によるパッド基材１２の補強効果が損なわれることはない。また、乗員がシートパッド１０に凭れる様な姿勢を採った場合などに補強支持部５２の中央部が後方へ撓んだ際に、パッド基材１２を挟んでシートフレームＳＦが第１の支持片５８の円弧状凹部５８ａに噛み合うことで、埋設された補強部材３０がパッド基材１２の所定位置に保持され、パッド基材１２の内部で補強部材３０が位置ずれするような不具合を効果的に防止できる。 Further, by connecting the left side reinforcing portion 32 and the right side reinforcing portion 33 of the reinforcing member 30 with the reinforcing support portion 52, the torsional rigidity of the reinforcing member 30 can be increased. Further, a reinforcing member 30 (reinforcing support portion 52) is embedded at a position corresponding to the front side of the seat frame SF that supports the seat pad 10, and support pieces 58 and 60 are formed in the reinforcing member 30 (reinforcing support portion 52). When the reinforcing member 30 is deformed so as to bend backward, the support pieces 58 and 60 are supported by the seat frame SF via the pad base material 12, thereby suppressing the deformation of the reinforcing member 30. Since damage and the like can be prevented, the reinforcing effect of the pad base material 12 by the reinforcing member 30 is not impaired. Further, when the central portion of the reinforcing support portion 52 bends backward when the occupant takes a posture of leaning against the seat pad 10, the seat frame SF sandwiches the pad base material 12 and the seat frame SF is the first support. By engaging with the arcuate recess 58a of the piece 58, the embedded reinforcing member 30 is held at a predetermined position of the pad base material 12, and it is effective that the reinforcing member 30 is displaced inside the pad base material 12. Can be prevented.

また、補強部材３０の左右の端部側に位置するよう第２の支持片６０を設けることで、シートパッド１０のサイドサポート部１６(ヘッドレスト装着部１８の左側支持壁部２２や右側支持壁部２４)を後方へ力が作用した場合に、パッド基材１２を介してシートフレームＳＦで第２の支持片６０が支持して補強部材３０の変形を抑制することで、サイドサポート部１６の変形を抑制でき、サイドサポート部１６の形状保持性を高めることができる。更に、各支持片５８,６０を補強部材３０の突出部５６に対応して設けることで、シートを装飾する飾り部材Ｋに設けた係合部Ｋａを、突出部５６に設けた嵌合孔５６ａに前側から差し込んだ際に補強部材３０がシートフレームＳＦで支持され、係合部Ｋａを嵌合孔５６ａに容易に係合することができる。 Further, by providing the second support piece 60 so as to be located on the left and right end sides of the reinforcing member 30, the side support portion 16 of the seat pad 10 (the left side support wall portion 22 and the right side support wall portion 24 of the headrest mounting portion 18) is provided. ) To the rear, the second support piece 60 is supported by the seat frame SF via the pad base material 12 to suppress the deformation of the reinforcing member 30, thereby suppressing the deformation of the side support portion 16. It is possible to improve the shape retention of the side support portion 16. Further, by providing the support pieces 58 and 60 corresponding to the protrusion 56 of the reinforcing member 30, the engaging portion Ka provided in the decorative member K for decorating the sheet is provided in the fitting hole 56a in the protrusion 56. When the reinforcing member 30 is inserted from the front side, the reinforcing member 30 is supported by the seat frame SF, and the engaging portion Ka can be easily engaged with the fitting hole 56a.

(別実施例)
次に、車両用のシートパッドの製造方法の別実施例について説明する。なお、別実施例に係る車両用のシートパッドの製造方法は、基本的に前述した実施例の構成と共通しており、共通する部分に関しては、同一の符号を付して詳細な説明を省略する。 (Another example)
Next, another embodiment of the method for manufacturing a seat pad for a vehicle will be described. The method for manufacturing a seat pad for a vehicle according to another embodiment is basically the same as the configuration of the above-described embodiment, and the common parts are designated by the same reference numerals and detailed description thereof will be omitted. do.

別実施例に係る車両用のシートパッドの製造方法では、補強部材３０における突出部５６の後方開口部５６ｂをシール材５７により塞ぐことなく、突出部５６が後方に開口した状態のままパッド基材１２に埋設するように構成される。この別実施例に係る成形型１１０を構成する第２の上型１０２には、図１１に示すように、型閉めした際に、第２の上型１０２に設けた係合突部１０４が補強部材３０(補強支持部５２)に当接すると共に、突出部５６の後方開口部５６ｂ(嵌合孔５６ａと反対側で開口する開口部)を、係合突部１０４により塞ぐよう構成されている。このように、突出部５６において嵌合孔５６ａと反対側で開口する後方開口部５６ｂを係合突部１０４により塞ぐことで、後方開口部５６ｂをシール材５７等により塞ぐ必要がなく、作業工数を低減できる利点がある。 In the method for manufacturing a seat pad for a vehicle according to another embodiment, the pad base material is in a state where the protruding portion 56 is opened rearward without blocking the rear opening 56b of the protruding portion 56 in the reinforcing member 30 with the sealing material 57. It is configured to be buried in 12. As shown in FIG. 11, the second upper mold 102 constituting the molding mold 110 according to the other embodiment is reinforced by the engaging protrusion 104 provided on the second upper mold 102 when the mold is closed. It is configured to abut on the member 30 (reinforcing support portion 52) and to close the rear opening 56b (opening on the opposite side of the fitting hole 56a) of the protruding portion 56 by the engaging protrusion 104. In this way, by closing the rear opening 56b that opens on the opposite side of the fitting hole 56a in the protruding portion 56 with the engaging protrusion 104, it is not necessary to close the rear opening 56b with the sealing material 57 or the like, and the work man-hours There is an advantage that can be reduced.

(変更例)
本発明に係る車両用のシートパッドの製造方法は、実施例に例示した形態に限らず種々の変更が可能である。以下に、変更例の一例を示す。
(１) 車両用シートのシートバックに用いられるシートパッドの製造を例にしたが、これに限られるものではなく、乗員が着座するシートクッションに用いられるシートパッドの製造に採用することもできる。
(２) 実施例では、係合突部と位置規制突部とを成形型を構成する異なる分割型(第１の上型と第２の上型)に設けるようにしたが、同一の分割型に設けることもできる。また、成形型を構成する分割型の形状や数は、実施例に示したものに限られるものではなく、シートパッドの形状に合わせて適宜に決定することができる。
(３) 補強部材は左右対称に形成する必要はなく、パッド基材の外周縁に倣う形状に形成されていればよい。また、パッド基材の外周前縁に倣うよう補強部材を形成したが、パッド基材の外周後縁に倣うよう補強部材を形成して後縁に沿うようパッド基材の外表面側に補強部材を埋設するようにしてもよい。
(４) 補強部材を合成樹脂により一体成形するようにしたが、金属等により形成してもよく、また複数の部材を組み合わせて補強部材を形成するようにしてもよい。 (Change example)
The method for manufacturing a seat pad for a vehicle according to the present invention is not limited to the embodiment exemplified, and various changes can be made. An example of the modification is shown below.
(1) The manufacturing of a seat pad used for a seat back of a vehicle seat is taken as an example, but the present invention is not limited to this, and it can also be used for manufacturing a seat pad used for a seat cushion on which an occupant sits.
(2) In the embodiment, the engaging protrusion and the position-restricting protrusion are provided in different split molds (first upper mold and second upper mold) constituting the molding mold, but the same split mold is provided. It can also be installed in. Further, the shape and number of the split molds constituting the molding mold are not limited to those shown in the examples, and can be appropriately determined according to the shape of the seat pad.
(3) The reinforcing member does not need to be formed symmetrically, as long as it is formed in a shape that follows the outer peripheral edge of the pad base material. Further, although the reinforcing member was formed to follow the outer peripheral leading edge of the pad base material, the reinforcing member was formed to follow the outer peripheral trailing edge of the pad base material and the reinforcing member was formed on the outer surface side of the pad base material along the trailing edge. May be buried.
(4) Although the reinforcing member is integrally molded with synthetic resin, it may be formed of metal or the like, or a plurality of members may be combined to form the reinforcing member.

１２パッド基材，１８ヘッドレスト装着部，２２左側支持壁部，
２４右側支持壁部，２６後側支持壁部，３０補強部材，
４８第２の上側補強壁部(補強部)，５６突出部，５６ａ嵌合孔，７０成形型
７２下型(分割型)，７３本体部成形面(成形面、第１の成形面)
７５後側支持壁部成形面(第２の成形面)，７６左側支持壁部成形面(第３の成形面)
７７右側支持壁部成形面(第４の成形面)，７８嵌合突部
８２第２の上型(別の分割型)，９２係合突部，９４位置規制突部 12 Pad base material, 18 Headrest mounting part, 22 Left support wall part,
24 Right side support wall, 26 Rear support wall, 30 Reinforcing member,
48 Second upper reinforcing wall part (reinforcing part), 56 protruding part, 56a fitting hole, 70 molding mold 72 lower mold (divided type), 73 main body molding surface (molding surface, first molding surface)
75 Rear support wall molded surface (second molded surface), 76 Left support wall molded surface (third molded surface)
77 Right support wall molded surface (fourth molded surface), 78 Fitting protrusion 82 Second upper mold (another split mold), 92 Engagement protrusion, 94 Position regulation protrusion

Claims

In a method for manufacturing a seat pad for a vehicle in which a pad base material made of a foam is formed by foaming a foaming raw material in a molding mold composed of a plurality of split molds.
The fitting hole opened at the protruding end of the protruding portion provided in the reinforcing member formed to imitate the curved outer peripheral edge of the pad base material is the split type in which the fitting protrusion constituting the molding mold is formed. The reinforcing member is installed in a state where it is fitted to the fitting protrusion and the protruding end of the protruding portion is in contact with the molding surface of the split type.
The split mold having the fitting protrusion formed by closing the mold with the engaging protrusion provided in another split mold facing the split mold is brought into contact with the reinforcing member to form the fitting protrusion. The reinforcing member is sandwiched between the mold and the engaging protrusion,
With the reinforcing member sandwiched, the foaming raw material is foamed in the molding mold to form the pad base material.
By removing the pad base material from the molding die, the sheet in which the fitting hole of the reinforcing member is opened on the outer surface in a state where the reinforcing member is embedded on the outer surface side along the curved outer peripheral edge. A method of manufacturing a seat pad for a vehicle, characterized in that the pad is manufactured.

With the molding die closed, the molding die is formed with respect to the reinforcing portion of the reinforcing member extending deviated from the fitting position where the fitting hole is fitted to the fitting protrusion. The molding die in a state where the position-regulating protrusion provided on any of the split dies is in contact with the edge on the other end side of the molding surface of the split die in which the fitting protrusion of the reinforcing portion is formed. The method for manufacturing a seat pad for a vehicle according to claim 1, wherein the foaming raw material is foamed inside.

In the split mold in which the fitting protrusion is formed, the main body portion of the pad base material is located above the first molding surface on one end side of the first molding surface for molding the main body portion of the pad base material. A second molding surface for molding the rear support wall portion located behind the upper part of the pad base is provided, and the pad base is located on one side of the second molding surface below the second molding surface. A third molding surface for molding the left side support wall portion located on the upper left side of the main body portion of the material is provided, and the other side portion of the second molding surface is located below the second molding surface. A fourth molding surface for molding the right support wall portion located on the upper right side of the main body portion of the pad base material is provided.
It extends along the edge portion of the second molding surface that is separated from the first molding surface, the third molding surface, and the lower edge portion of the fourth molding surface that is separated from the second molding surface. Install the reinforcing member
By removing the pad base material from which the foaming raw material is foamed in the mold from the mold, the front of the concave headrest mounting portion formed on the upper part of the main body and opened upward and forward. The method for manufacturing a seat pad for a vehicle according to claim 1 or 2, wherein the reinforcing member is embedded along the opening edge and the upper opening edge.

The fitting hole is fitted into the fitting protrusion formed on the first molding surface, and the reinforcing end is in contact with the molding surface of the first molding surface. Install the parts,
With the molding die closed, the molding die is applied to the reinforcing portion of the reinforcing member extending along the edge portion of the second molding surface separated from the first molding surface. In a state where the position-regulating protrusion provided in any of the constituent split molds is in contact with the edge of the reinforcing portion on the other end side of the first molding surface, the foaming raw material is placed in the molding die. The method for manufacturing a seat pad for a vehicle according to claim 3, wherein the seat pad is foamed.

The invention according to any one of claims 1 to 4, wherein the opening of the protruding portion that opens on the opposite side of the fitting hole when the mold is closed is closed by the engaging protrusion. How to make a seat pad for a vehicle.