JP2011110798A - Support material, foam molding member and foam molding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a support material preventing formation of voids in a foam molding member, the foam molding member using the support material, and a foam molding method. <P>SOLUTION: The support material 1 has a central part 2 disposed along the back face of the back rest part 12 of a seat pad body 11, and side parts 3, 4 which are respectively connected to both side edges of the central part 2 and are disposed respectively along back faces of right and left both side parts 13, 14 of the seat pad body 11. The side parts 3, 4 are each composed of a high air permeable material made of a cloth material with a basis weight of 80-140 g/m<SP>2</SP>. The central part 2 is made of a cloth material having a basis weight larger than 80-140 g/m<SP>2</SP>. In the foam molding of a seat pad 10, the support material 1 is mounted to the core 23 of a mold 20 for foam molding. Here, side ends of the side parts 3, 4 of the support material 1 are each located on the vicinity of a joint face P<SB>2</SB>of an upper mold 21 and the core 23. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention provides a support material that is disposed along at least a part of the outer surface of a foam molded body and integrated with the foam molded body, and a foam molded member in which the support material and the foam molded body are integrated. In particular, the present invention relates to a foam molding method, and more particularly, to a support material, a foam molding member, and a foam molding method suitable for application to a seat pad of a vehicle seat.

  A vehicle seat or a seat such as a sofa installed in a house includes a seat pad made of a foamed synthetic resin such as a soft polyurethane foam or a semi-rigid polyurethane foam, and a skin material mounted on the surface of the seat pad.

  In order to reinforce the seat pad, a support material made of press felt or the like may be provided on the back surface (surface opposite to the seated person) of the seat pad (Japanese Patent Laid-Open No. 2005-185350). This support material is integrated with the seat pad by integral molding.

  As a method for integrally forming such a seat pad with a support material, there is a method described in JP-A-2005-319123. FIG. 4 is a sectional view of a mold showing the foam molding method of the same number, and FIG. 5 is a sectional view of a seat pad with a support material molded by this method. As shown in FIG. 4, the mold 100 includes an upper mold 101, a lower mold 102, and a core 103 set on the upper mold 101. Reference numeral 104 denotes a hinge connecting the upper mold 101 and the lower mold 102. An exhaust port 105 for exhausting the gas in the mold 100 to the outside of the mold 100 is provided on the mating surface of the upper mold 101 and the lower mold 102. In the mold 100, the seat pad 120 is molded in a posture in which the front surface (surface on the seated person side) faces downward. That is, the front surface of the seat pad 120 is molded by the cavity surface of the lower mold 102, and the rear surface of the seat pad 120 is molded by the cavity surfaces of the upper mold 101 and the core 103.

  When foam-molding the seat pad 120, the core 103 is set on the upper mold 101 by covering the cavity surface of the core 103 with the support material 110. Next, a urethane raw material is supplied into the lower mold 102 and the mold is clamped to foam the urethane raw material. At this time, as the urethane expands, the gas in the mold 100 is discharged out of the mold 100 from the exhaust port 105. After the foamed urethane is solidified, the mold is opened and removed to obtain a seat pad 120 in which the support material 110 is integrally formed on the back surface as shown in FIG.

JP 2005-185350 A JP-A-2005-319123

JP-A-2005-185350 describes that a press felt having a basis weight of 400 to 2000 g / m ² is used as the support material. If the support material 110 having such a high basis weight is used, foaming is performed. Gases between the seat pad main body 121 and the support material 110 are difficult to be discharged during molding, and voids (voids due to residual gas) are formed in the seat pad main body 121, which may be defective.

  An object of the present invention is to provide a support material in which voids are prevented from being formed in a foam molded member, and a foam molded member and a foam molding method using the support material.

The support material of the present invention (Claim 1) is disposed along at least a part of the outer surface of the foam molded body, and is a support material integrated with the foam molded body, and at least one of the peripheral portions of the support material. The portion is made of a highly breathable material having an air permeability of 50 to 200 cc / cm ² / sec.

  The support material according to claim 2 is characterized in that, in claim 1, the non-peripheral portion of the support material is made of a low air permeability material having a smaller air flow rate than the high air permeability material. .

Support material according to claim 3, in claim 1 or 2, wherein the high permeability material is one that basis weight is equal to or formed of cloth material of 80~140g / m ^2.

  According to a fourth aspect of the present invention, there is provided the support material according to the third aspect, wherein the low air permeability material is a cloth material having a larger basis weight than the high air permeability material.

  The support material according to claim 5 is any one of claims 1 to 4, wherein the foamed molded body is a seat pad, and the support material is disposed along the back surface of the seat pad. And at least a part of the support material disposed on the left and right side portions of the back surface of the seat pad is made of the highly breathable material.

  The foam molded member according to claim 6 includes a foam molded body and the support material according to any one of claims 1 to 5 disposed along at least a part of an outer surface of the foam molded body. The support material is integrated with the foamed molded body.

  According to a seventh aspect of the present invention, in the foam molded member according to the sixth aspect, the foam molded body is a seat pad.

  The foam molding method according to claim 8 is characterized in that the foam molding is foamed by attaching the support material according to any one of claims 1 to 5 to at least a part of the inner surface of the mold. Is.

  A foam molding method according to a ninth aspect is characterized in that, in the eighth aspect, at least a part of a peripheral portion of the support material made of the highly air-permeable material is positioned in the vicinity of a mating surface of the mold. It is.

As for the support material of this invention, at least one part of the peripheral part is comprised with the highly air permeable material whose air flow rate is 50-200cc / cm < ² > / sec. Therefore, during foam molding of the foam-molded body with a support material of the present invention, the gas between the support material and the foam-molded body is discharged from between these through the portion made of the highly breathable material of the support material. The Thereby, it is prevented that the void by a residual gas is formed in a foaming molding, and the yield of a foaming molding improves.

In addition, this ventilation | gas_flowing amount has shown the quantity (cc) which can pass the unit area (1 cm <2>) of this highly air permeable material in 1 ^second at the differential pressure | voltage 125Pa. This air flow rate is measured based on the Frazier method. That is, test pieces having an outer dimension of about 20 cm × 20 cm are taken from five different surface samples made of a highly breathable material, and a test piece is attached to one end of a cylinder of the tester using a Frazier type tester. After installation, adjust the suction fan so that the inclination type barometer shows a pressure of 125 Pa with an adjustable resistor, and the test machine shows the pressure indicated by the vertical barometer and the type of air hole used. The amount of air passing through the test piece is obtained from the attached table, and the average value of the five test pieces is calculated to obtain the air flow rate of the highly breathable material.

  As described in claim 2, the non-peripheral portion of the support material may be made of a low air permeability material. Even in this case, the gas between the support material and the foamed molded body is discharged from between the peripheral portions of the support material made of a highly breathable material.

As a third aspect, as the highly breathable material, a cloth material having a basis weight of 80 to 140 g / m ² and a ventilation amount of 50 to 200 cc / cm ² / sec is preferable. If the fabric weight as the highly breathable material is less than 80 g / m ² or the breath volume is greater than 200 cc / cm ² / sec, the strength as the support material is insufficient, and the fabric weight is 140 g / m ^2. If it is larger than m ² or the air flow rate is smaller than 50 cc / cm ² / sec, there is a possibility that the exhaust action by the support material will not be sufficiently achieved during foam molding.

  As a fourth aspect of the present invention, as the low air permeability material for the non-peripheral portion of the support material, a cloth material having a larger basis weight than the high air permeability material is suitable. Thereby, the intensity | strength of a support material sufficient to reinforce a foaming molding can be ensured.

  As described in claims 5 and 7, the present invention is suitable for a seat pad support material and a seat pad provided with the support material. In addition, the back surface of a seat pad means the surface on the opposite side to the seated person of a seat pad. That is, for example, if the seat pad constitutes a seat cushion (seat portion), the back surface of the seat cushion means the bottom surface, and if it constitutes a seat back (back portion), the back surface of the seat back. Means the back. The front surface of the seat pad refers to the surface on the seat pad side of the seat pad.

  As described in claim 9, when the foam-molded article with a support material of the present invention is foam-molded with a mold, at least a part of the peripheral portion made of a highly breathable material of the support material is positioned near the mating surface of the mold. It is preferable. Normally, an exhaust port for discharging the gas in the mold out of the mold is provided on the mating surface of the mold. Accordingly, by positioning at least a part of the peripheral edge of the support material, which is made of a highly breathable material, in the vicinity of the mating surface of the mold, the gas between the support material and the foam molded body is subjected to foam molding. The support material is led to the mating surface of the mold through the peripheral edge, and is discharged out of the mold from the exhaust port of the mating surface. Thereby, it becomes possible to exhaust the gas between a support material and a foaming molding body out of a metal mold | die efficiently.

It is a top view of the support material which concerns on embodiment. It is sectional drawing of the seat pad provided with the support material of FIG. It is sectional drawing of the metal mold | die which shows the foam molding method of the seat pad of FIG. It is sectional drawing of the metal mold | die which shows the foam molding method of the seat pad with a support material which concerns on a prior art example. It is sectional drawing of the seat pad with a support material which concerns on a prior art example.

  Embodiments of the present invention will be described below with reference to the drawings. In the following embodiments, the support material is provided on a seat pad of a vehicle seat, but the present invention is a support material provided on a foam molding member other than a seat or a seat for other uses. Is also applicable.

  FIG. 1 is a plan view of a support material according to the embodiment, FIG. 2 (a) is a cross-sectional view of a seat pad as a foam molded member integrally formed with the support material, and FIG. 2 (b) is a second view. FIG. 3 (a) is an enlarged view of the vicinity of the side portion, and FIGS. 3 (a) to 3 (c) are cross-sectional views of a mold showing a foam molding method of the seat pad. 3 (a) shows the start of foam molding, FIG. 3 (b) shows the middle of foam molding, and FIG. 3 (c) shows the completion of foam molding.

  In this embodiment, the seat pad 10 as a foam molded member is a seat back pad that constitutes a seat back of a vehicle seat. The seat pad 10 includes a seat pad main body 11 made of a foamed synthetic resin such as a soft urethane foam or a semi-rigid urethane foam, and a planar support material 1 integrally formed on the back surface of the seat pad main body 11. . As shown in FIG. 2 (a), the seat pad main body 11 has a back rest 12 that hits the back of the seated person, and side portions 13 and 14 provided on the left and right sides of the back rest 12, respectively. . On the back surfaces of the side portions 13 and 14, recessed grooves 13a and 14a with which seat frames (not shown) are respectively engaged are formed. A part of a skin material (not shown) to be mounted on the surface of the seat pad 10 is drawn in the vicinity of the boundary between the back pad portion 12 on the front side of the seat pad body 10 and the left and right side portions 3 and 4. A groove 12a to be locked is formed.

  The support material 1 is connected to the center portion 2 disposed along the back surface of the backrest portion 12 and the left and right side edges of the center portion 2, respectively, along the back surfaces of the left and right side portions 13 and 14. It has side parts 3 and 4 to be arranged. In this embodiment, as shown in FIG. 1, the central portion 2 and the side portions 3 and 4 are formed of separate cloth pieces, and the support material 1 is attached to the back surface of the seat pad main body 11. It is sewn so as to have a three-dimensional shape. Reference numeral 5 in FIGS. 2 (a) and 2 (b) denotes a sewing thread in which the opposite edges of the central portion 2 and the side portions 3 and 4 are stitched together. As shown in FIG. 2 (b), the stitched portion (stitch 5) between the central portion 2 and each of the side portions 3 and 4 is near the left and right ends of the backrest portion 12 (each groove portion on both sides of the backrest portion 12) It is arranged in a range R slightly from 12a to the back end portion 12 on the opposite side to the back rest portion 12 of the deepest curved surface of the groove portions 13a, 14a. Is preferred. In addition, arrangement | positioning of the stitching | suture part of this center part 2 and each side part 3 and 4 is not limited to this.

In this embodiment, the side portions 3 and 4 are made of a highly breathable material. Specifically, each of the side portions 3 and 4 is preferably made of a cloth material having a basis weight of 80 to 140 g / m ² and a ventilation amount of 50 to 200 cc / cm ² / sec. As described above, the air flow rate indicates the amount (cc) of air that can pass through 1 cm ² of the cloth material per ^second at a differential pressure of 125 Pa, and is measured by the Frazier method. The thickness of the highly air-permeable material constituting the side portions 3 and 4 is preferably 0.7 mm or more, and preferably 3.0 mm or less, particularly 2.5 mm or less. The air permeability of the highly air permeable material constituting the side portions 3 and 4 is preferably 50 cc / cm ² / sec or more, particularly 90 cc / cm ² / sec or more. The upper limit of the air permeability of the highly air permeable material is not particularly limited as long as the function (strength and the like) as the support material of the side portions 3 and 4 is not impaired, for example, 200 cc / cm ² / sec or less. It is preferably 150 cc / cm ² / sec or less. In addition, as a fabric material which comprises each side part 3 and 4, you may use any form of fabric materials, such as a woven fabric, a knitted fabric, and a nonwoven fabric. As this cloth material, for example, Tafnel (registered trademark) made of polypropylene, Borans (registered trademark) made of polyester, and the like are suitable. Each of the side portions 3 and 4 may be composed of a single cloth material, and a plurality of cloth materials having a small basis weight and a large ventilation amount, and the total basis weight and ventilation rate are within the above ranges. It may be a configuration in which layers are overlapped so as to be. If the fabric weight as the highly breathable material is less than 80 g / m ² or the breath volume is greater than 200 cc / cm ² / sec, the strength as the support material is insufficient, and the fabric weight is 140 g / m ^2. If it is larger than m ² or the air flow rate is smaller than 50 cc / cm ² / sec, there is a possibility that the exhaust action by the support material will not be sufficiently achieved during foam molding.

Since the center part 2 reinforces the backrest part 12 on which the back of the seated person hits, it is preferable to determine the basis weight with more importance on strength. As the cloth material constituting the central portion 2, it is preferable to use one having a basis weight of 80 to 140 g / m ^2, particularly 90 to 140 g / m ² . That is, the central portion 2 is made of a low air permeability material having a larger basis weight than the side piece portions 3 and 4. The cloth material constituting the central portion 2 may be in any form such as a woven fabric, a knitted fabric, or a non-woven fabric. As the cloth material constituting the central portion 2, for example, Tafnel (registered trademark) made of polypropylene, Borans (registered trademark) made of polyester, and the like are suitable. The material of the cloth material constituting the central portion 2 may be the same as or different from the side portions 3 and 4. The central portion 2 may also be composed of a single cloth material, or may be a structure in which a plurality of cloth materials are layered so that the total fabric weight is within the above range. If the fabric weight constituting the central portion 2 is less than 80 g / m ² , the air permeability is good, but the strength may be insufficient to reinforce the backrest portion 12. On the other hand, if the basis weight is larger than 140 g / m ² , the strength is sufficient, but the thickness may be excessively increased or the cost may increase.

  Next, a method for forming the seat pad 10 provided with the support material 1 will be described.

In this embodiment, the seat pad molding die 20 includes an upper die 21, a lower die 22, and a core 23. The mating surface P ₁ between the upper mold 21 and the lower mold 22 is provided with an exhaust port 24 for discharging the gas in the mold 20. Further, an exhaust passage 25 for discharging the gas in the mold 20 is also provided on the mating surface P < _b > ₂ between the upper mold 21 and the core 23. An exhaust device 26 that exhausts gas from the exhaust passage 25 is attached to the upper mold 21. The seat pad 10 is molded in a posture in which the front surface (surface on the seated person side) faces downward in the mold 20. That is, the front surface of the seat pad 10 is molded by the cavity inner surface (bottom surface) of the lower mold 22, and the rear surface of the seat pad 10 is molded by the cavity inner surfaces (ceiling surface) of the upper mold 21 and the core 23. The backrest portion 12 is formed by the lower surface of the core 23 in the clamped state. Convex portions 23a and 23b for forming the concave grooves 13a and 14a on the back surfaces of the side portions 13 and 14 respectively project from the left and right ends of the core 23.

When molding the seat pad 10, first, a release agent is applied to the cavity inner surfaces of the upper mold 21, the lower mold 22 and the core 23, and then the support material 1 is attached to the cavity inner surface of the core 23. As shown in FIG. 3 (a), when the support material 1 is mounted on the inner surface of the cavity of the core 23, the side end portions of the side portions 3 and 4 of the support material 1 are connected to the upper die 21 and the middle. located in the vicinity of the mating surface P ₂ of the child 23. Next, the urethane raw material U is supplied into the lower mold 22 and the mold is clamped to foam the urethane raw material. The foamed urethane expands so as to fill the inside of the mold 20 as shown in FIGS. 3 (b) to 3 (c). At this time, the gas in the mold 20 is discharged from the exhaust port 24 and the exhaust passage 25 to the outside of the mold 20 with the expansion of the urethane. The seat pad body 11 is constituted by the foamed urethane. After the foamed urethane is solidified, the mold is opened and removed to obtain a seat pad 10 in which the support material 1 is integrally formed on the back as shown in FIG.

In the the support member 1, each side portion 3, 4 located in the vicinity of the mating surface P ₂ of the mold 20 is constituted by highly breathable material. Therefore, at the time of foam molding, the gas between the support material 1 and the seat pad main body 11 is guided to the exhaust passage 25 through the side portions 3 and 4, and is discharged out of the mold 20 from the exhaust passage 25. Is done. As a result, voids due to residual gas are prevented from being formed on the foamed seat pad 10. As a result, the yield of the seat pad 10 is improved.

  In this embodiment, the center portion 2 of the support material 1 is composed of a cloth material having a relatively large basis weight. Therefore, the back portion 12 of the seat pad 10 is sufficiently reinforced by the central portion 2. In other words, the support material 1 has a high exhausting action when the seat pad 10 is foam-molded, and can sufficiently reinforce the backrest portion 12 of the foam-molded seat pad 10.

  In general, a fabric material with a small basis weight is often relatively inexpensive, and a fabric material with a larger basis weight tends to be more expensive. In the above-mentioned JP-A-2005-319123, the entire support material is composed of a single continuous cloth material. That is, in the same number, the support material is made of a cloth material having the same basis weight in both the central portion and both side portions. In this case, in order to ensure sufficient strength to reinforce the seat pad main body backing part at the center of the support material, it is necessary to use a cloth material with a relatively large basis weight. Since not only the central part of the material but also the side parts on both sides are formed of this cloth material, the material cost of the support material increases. On the other hand, in this embodiment, the central portion 2 and the side portions 3 and 4 of the support material 1 are configured by separate cloth materials, and a cloth material having a relatively large basis weight is formed in the central portion 2. Used is a cloth material with a relatively small basis weight for each of the side portions 3 and 4. Therefore, it is possible to use a relatively inexpensive cloth material as the cloth material constituting each of the side portions 3 and 4, thereby providing sufficient strength to reinforce the back pad portion 12 of the seat pad body 11. While securing, it is possible to reduce the material cost of the support material 1.

[Other configurations]
In the above embodiment, the support material 1 is obtained by stitching three cloth materials constituting the central portion 2 and the side portions 3 and 4, but the division of the cloth material constituting the support material 1 is as follows. It is not limited to this. For example, the support material 1 may be obtained by stitching two or four or more cloth materials. Or you may comprise the whole support material 1 by the cloth material which consists of a highly air permeable material. In this case, a reinforcing cloth material may be overlaid on a portion of the support material 1 that overlaps the back pad 12 of the seat pad main body 11.

  In the above embodiment, the mold 20 is composed of the upper mold 21, the lower mold 22 and the core 23, and the support material 1 is attached to the core 23 in the same manner as in the aforementioned Japanese Patent Application Laid-Open No. 2005-319123. In this case, foam molding of the seat pad 10 is performed, but the configuration of the mold 20 is not limited to this. For example, the mold 20 may be provided with two or more cores as necessary, and may be composed of only the upper mold 21 and the lower mold 22.

  In the above embodiment, the seat pad 10 is a seat back pad for a vehicle seat, but the seat pad may be a seat cushion pad. The present invention can also be applied to foamed molded articles other than seat pads, for example, cushion pads that constitute headrests, armrests, and the like. The present invention can also be applied to seat pads for seats other than those for vehicles, and can also be applied to foam molded members other than the cushion pads.

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

DESCRIPTION OF SYMBOLS 1 Support material 2 Center part 3, 4 Side part 5 Sewing thread 10 Seat pad 11 Seat pad main body 12 Backing part 13, 14 Side part 20 Mold 21 Upper mold 22 Lower mold 23 Core 24 Exhaust port 25 Exhaust flow path 25

Claims (9)

In the support material that is disposed along at least a part of the outer surface of the foam molded body and integrated with the foam molded body,
A support material, characterized in that at least a part of the peripheral edge of the support material is made of a highly air permeable material having an air permeability of 50 to 200 cc / cm ² / sec.   The support material according to claim 1, wherein the non-peripheral portion of the support material is made of a low air permeability material having a smaller air permeability than the high air permeability material. 3. The support material according to claim 1, wherein the highly breathable material is a cloth material having a basis weight of 80 to 140 g / m < ² >.   The support material according to claim 3, wherein the low air permeability material is a cloth material having a larger basis weight than the high air permeability material. In any 1 item | term of the Claims 1 thru | or 4, The said foaming molding is a seat pad,
The support material is disposed along the back surface of the seat pad,
A support material, characterized in that at least a part of the support material arranged on the left and right side portions of the back surface of the seat pad is made of the highly breathable material.   A foam molded article and a support material according to any one of claims 1 to 5 disposed along at least a part of an outer surface of the foam molded article, wherein the support material is the foam molded article. Foam molded member that is integrated with.   The foam molded member according to claim 6, wherein the foam molded body is a seat pad.   A foam molding method, wherein the foam molding is molded by attaching the support material according to any one of claims 1 to 5 to at least a part of an inner surface of the mold.   9. The foam molding method according to claim 8, wherein at least a part of a peripheral edge portion of the support material made of the highly air-permeable material is positioned in the vicinity of a mating surface of the mold.

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