JP2018030391A - Sheet member for vehicle and method for producing the same - Google Patents

Abstract

A vehicle seat member manufacturing method capable of obtaining a vehicle seat member with high dimensional accuracy is provided. A vehicle seat member including a frame material and a foamed resin molded body in which the frame material is embedded is manufactured. In this manufacturing method, in the arranging step, the weight 37 is arranged in the mold 7 together with the frame material 20 so that the weight 37 having a density larger than the density of the foamed resin molded body 30 is arranged in the extending portion 36. In the heat dissipation step, after removing the foamed resin molded body 30 at least, the weight of the weight 37 keeps the orientation of the foamed resin molded body 30 in a direction to suppress the deformation due to the thermal contraction of the extending portion 36, The heat of the molded body 30 is dissipated. [Selection] Figure 6

Description

  The present invention relates to a vehicle seat member and a method for manufacturing the same.

  As a vehicle seat member for an automobile or the like, for example, a vehicle seat member in which a frame material is integrally formed with a foamed resin molded body is known (see, for example, Patent Documents 1 and 2).

  In Patent Document 3, a vehicle seat member manufacturing method in which a frame member provided with a latch for fixing to a vehicle and a connecting member for connecting it is embedded in a foamed particle molded body and integrally molded. Is disclosed. The connecting member is embedded in the front side of the foamed particle molded body along the longitudinal direction of the vehicle seat member. In Patent Document 3, a portion of the foamed particle molded body in which the pillar portion of the latching tool is embedded has a cut in the longitudinal direction outward portion of the vehicle seat member that extends outward from the pillar portion in the longitudinal direction. It is described to do.

JP 2001-161508 A International Publication No. WO2015 / 159691 International Publication WO2016 / 042759

  As described above, in the vehicle seats described in Patent Documents 1 to 3, the frame material is integrally formed inside the foamed resin molded body constituting the vehicle seat member. Since the frame material and the foamed resin molding are made of different materials, their thermal expansion coefficients are different. For this reason, the degree of thermal expansion and thermal contraction differs between the portion of the foamed resin molded body in which the frame material does not exist and the portion of the foamed resin in which the frame material is embedded.

  Therefore, for example, the portion of the foamed resin in which the frame material is not present in the foamed resin molded body due to heat dissipation during demolding of the foamed resin molded body after molding, heat input to the vehicle seat member, or the like has a predetermined shape. It is assumed that the material is slightly deformed.

  The present invention disclosed in the present specification to solve the above problems is a method for manufacturing a vehicle seat member including a frame material and a foamed resin molded body in which the frame material is embedded, and the vehicle seat An arrangement step of arranging the frame material in a mold so that the frame material is arranged along the contour of the vehicle seat member in plan view of the member; and the frame material is embedded in the mold And a foam including a frame-shaped portion that forms an outline of the vehicle seat member, and an extending portion that extends inward from the frame-shaped portion so as to pass through the frame-shaped portion inside the frame-shaped portion. A molding step of molding a resin molded body, and a heat release step of releasing the foamed resin molded body from the molding die and dissipating heat remaining in the foamed resin molded body after molding. In the extension, After placing the weight in the mold together with the frame material so that a weight having a density greater than the density of the foamed resin molded body is disposed, and at least removing the foamed resin molded body in the heat dissipation step The weight of the foamed resin molded body is dissipated by the dead weight of the weight while maintaining the posture of the foamed resin molded body in a direction in which deformation due to thermal contraction of the extending portion is suppressed.

  In the method for manufacturing a vehicle seat member, the frame-shaped portion of the foamed resin molded body in which the frame material is embedded and the extended portion that extends inside the frame-shaped portion and does not have the frame material are apparent. The amount of heat shrinkage is different. As a result, compressive stress and tensile stress act as thermal stress nonuniformly on the extension part surrounded by the frame-like part, and the extension part is easily deformed. In the present invention, this deformation can be suppressed. .

  That is, in the present invention, in the heat dissipation process, after removing the foamed resin molded body, the foamed resin molded body is held while maintaining the posture of the foamed resin molded body in a direction to suppress deformation due to thermal contraction of the extending portion by the weight of the weight. The heat at the time of molding remaining in the resin molded body is dissipated (the foamed molded body is allowed to cool). Thereby, when the heat | fever at the time of shaping | molding of a foamed resin molding is dissipated, the deformation | transformation of the extension part resulting from thermal contraction can be suppressed with the dead weight of a weight.

  As a more preferable aspect, the frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous, and in the molding step, the extending portion is defined as the opposed portion. It shape | molds so that it may extend over between.

  Here, since both sides of the extended portion are constrained by the portion of the frame-like portion in which the continuous portion of the frame material is embedded, the extended portion is easily deformed by thermal contraction in the heat dissipation process. However, even in such a case, according to this aspect, by arranging the weight in the formed extension portion, the deformation of the extension portion can be suppressed by the weight of the weight in the heat dissipation process. .

  As a more preferable aspect, the outline of the vehicle seat member in the plan view has a shape having a short side direction and a long side direction, and in the molding step, the extending portion is opposed to the frame-like portion. A portion is formed so as to include at least a first extending portion extending along the longitudinal direction over the portion, and the weight is provided at a position where the first extending portion is formed in the arranging step. Place.

  Here, the first extending portion formed along the longitudinal direction is easily deformed by heat shrinkage. According to this aspect, the weight is arranged in the molded first extending portion. It is possible to suppress deformation of the first extending portion due to heat shrinkage in the heat dissipation process.

  As a more preferred aspect, the weight is a magnetic body, and a magnet for fixing the weight with a magnetic force in the molded body is attached to the mold, and the weight is fixed to the magnet in the arranging step. To do. According to this aspect, since the weight of the magnetic body can be fixed to the magnet in the placing step, the weight can be placed at a desired position of the extending portion when the foamed resin molded body is formed. Furthermore, when removing the foamed resin molding, the magnet can be easily removed from the weight together with the molding die.

  As a more preferable aspect, the frame member is circulated along the contour of the vehicle seat member. According to this aspect, since the frame member circulates along the contour of the vehicle seat member, the strength of the vehicle seat member can be increased. Here, when the frame material is circulated along the contour of the vehicle seat member, both sides of the extending portion are constrained and easily deformed by thermal contraction. Even in such a case, according to this aspect, by arranging the weight in the formed extension portion, the deformation of the extension portion can be suppressed by the weight of the weight in the heat dissipation step.

  In this specification, the vehicle seat member is further disclosed as the present invention. A vehicle seat member according to the present invention is a vehicle seat member including a frame material and a foamed resin molded body in which the frame material is embedded, and the frame material is a plan view of the vehicle seat member. The foamed resin molded body is disposed along the contour of the vehicle seat member, and the foamed resin molded body embeds the frame material and forms the contour of the vehicle seat member; and the frame-shaped portion An extension portion extending inwardly from the frame-like portion so as to pass the frame-like portion on the inner side of the extension portion, and in the extension portion, at a position to suppress deformation of the extension portion due to heat, A weight having a density larger than that of the foamed resin molded body is attached.

  When heat is input to the vehicle seat member (or when the input heat is dissipated), the frame-shaped portion in which the frame material is embedded in the foamed resin molded body, and the inside of the frame-shaped portion The apparent thermal expansion amount (thermal contraction amount) differs from the extended portion where the frame material does not exist. Thereby, in the extension part surrounded by the frame-like part, the compressive stress and the tensile stress act as the thermal stress non-uniformly, and the extension part is easily deformed. Since the weight is attached at a position to suppress the deformation of the extending portion due to heat, the deformation of the extending portion can be suppressed by the weight of the weight.

  As a more preferred aspect, the frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous, and the extending portion extends between the opposed portions. It is formed to extend.

  Here, since both sides of the extended portion are restrained by the frame-like portion in which the continuous portion of the frame material is embedded, such an extended portion is particularly easily deformed by thermal expansion and thermal contraction. Even in such a case, according to this aspect, by arranging the weight in the extending portion, the deformation of the extending portion can be suppressed by the weight of the weight.

  As a more preferred aspect, the outline of the vehicle seat member in the plan view is a shape having a short side direction and a long side direction, and the extending portion extends over a portion where the frame-like portion faces. A first extending portion along the longitudinal direction is included, and the weight is attached to the first extending portion. The first extending portion formed along the longitudinal direction is easily deformed due to thermal expansion and contraction. According to this aspect, the first extending portion can be deformed by its own weight by arranging the weight in the first extending portion. 1 The deformation of the extending portion can be suppressed.

  As a more preferred aspect, the frame material circulates along the contour of the vehicle seat member. According to this aspect, since the frame material circulates along the contour of the vehicle seat member, the strength of the vehicle seat member can be increased. Here, when the frame member is circulated along the contour of the vehicle seat member, both sides of the extending portion are constrained and easily deformed due to thermal expansion and contraction. Even in such a case, according to this aspect, since the weight is attached to the extending portion in a direction to suppress the deformation of the extending portion due to heat, the extension portion is deformed by its own weight. It can be suppressed more effectively.

  According to the method for manufacturing a vehicle seat member according to the present invention, a vehicle seat member with high dimensional accuracy can be obtained. Further, according to the vehicle seat member of the present invention, the dimensional accuracy of the vehicle seat member is ensured even when heat is input to the vehicle seat member or when the input heat is dissipated. can do.

It is the typical perspective view which looked at the vehicle seat member concerning a 1st embodiment of the present invention from the upper part side. It is the typical perspective view which looked at the vehicle seat member shown in FIG. 1 from the lower side. It is a top view of the vehicle seat member shown in FIG. It is a left view of the vehicle seat member shown in FIG. It is a typical perspective view for demonstrating the manufacturing method of the vehicle seat member shown in FIG. It is typical sectional drawing in the position corresponding to the II arrow directional cross section shown in FIG. (A) is a cross-sectional view of a state where pre-foamed resin particles are filled in a mold, and (b) is a foamed resin molded body obtained by foaming the pre-foamed particles from the state shown in (a). It is sectional drawing of the state which carried out, (c) is the figure which showed the state which removed the foamed resin molding from the state shown to (b) from the shaping | molding die. It is a figure for demonstrating the manufacturing method of the vehicle seat member used as a comparative example, (a) is sectional drawing of the state which expanded the pre-expanded particle and shape | molded the foamed resin molding, (b) These are the figures which showed the state which removed the foamed resin molding from the state shown to (a) from a shaping | molding die. It is a figure for demonstrating the manufacturing method of the vehicle seat member which concerns on 2nd Embodiment in the position corresponding to the II arrow cross section shown in FIG. 5, (a) is a pre-foaming resin in a shaping | molding die. It is sectional drawing of the state filled with particle | grains, (b) is sectional drawing of the state which expanded the pre-expanded particle from the state shown to (a), and shape | molded the foamed resin molding, (c) is It is the figure which showed the state which demolded the foamed resin molding from the state shown to (b). It is a figure for demonstrating the manufacturing method of the vehicle seat member which concerns on 3rd Embodiment in the position corresponding to the II arrow cross section shown in FIG. 5, (a) is a pre-foaming resin in a shaping | molding die. It is sectional drawing of the state filled with particle | grains, (b) is sectional drawing of the state which expanded the pre-expanded particle from the state shown to (a), and shape | molded the foamed resin molding, (c) is It is the figure which showed the state which demolded the foamed resin molding from the state shown to (b). It is the typical perspective view which looked at the vehicle seat member concerning other embodiments of the present invention from the lower part side. It is the typical perspective view which looked at the vehicle seat member concerning other embodiments of the present invention from the lower part side. It is the typical perspective view which looked at the vehicle seat member concerning other embodiments of the present invention from the lower part side.

  Hereinafter, several embodiments of a vehicle seat member and a vehicle seat according to the present invention will be described with reference to the drawings. However, the scope of the present invention is not limited to individual embodiments.

<First Embodiment>
1. About Vehicle Seat Member 10 A first embodiment of a vehicle seat member and a method for manufacturing the same will be described with reference to FIGS.
As shown in FIGS. 1 and 2, the vehicle seat member 10 includes a frame material 20 and a foamed resin molded body 30 in which at least a part of the frame material 20 is embedded as a basic configuration.

  Although there is no restriction | limiting in particular in the whole shape of the vehicle seat member 10, As shown in FIG. 3, the shape which is a rectangle by planar view is common. In this specification, a rectangle refers to a rectangle such as a rectangle or a square, and is not limited to a rectangle or a square, but may be a trapezoid or a parallelogram. In the present specification, the rectangle includes a case where the rectangle is a rough rectangle. For example, the corner may be rounded, or a part or all of the sides constituting the rectangle may be bent.

  In the present embodiment, as shown in FIG. 3, the contour S in a plan view of the vehicle seat member 10 is a rectangle having a short side and a long side, and has a shape having a short side direction and a long side direction. . The contour S includes, as four sides, a right edge portion sR and a left edge portion sL constituting a short side, a front edge portion sF and a rear edge portion sB constituting a long side, and corner portions constituting four corners. sC. In the present embodiment, the front, rear, left, and right refer to directions when the vehicle is viewed from the vehicle in a state where a passenger is seated in the vehicle.

  For example, as shown in FIG. 4, the vehicle seat member 10 of the present embodiment includes an upper seat member 50 such as a cushion material as appropriate from the upper surface 11 of the vehicle seat member 10, that is, the upper surface 31 side of the foamed resin molded body 30. Can be stacked to form the vehicle seat 1. Further, the vehicle seat member 10 may be covered with a cushion material or the like by an appropriate exterior material to form the vehicle seat 1.

1-1. About Frame Material 20 As shown in FIGS. 1 and 2, the frame material 20 is embedded in the foamed resin molded body 30 in order to give the required shape retention and strength. The frame material 20 is usually composed of a material whose dimensions do not substantially change compared to the foamed resin molded body 30 under the conditions for molding the foamed resin molded body 30, for example, a metal material such as steel or aluminum. is there.

  The frame member 20 includes first and second frame portions 21 and 22 that extend into the foamed resin molded body 30 along the contour S of the vehicle seat member 10 in plan view, and the first and second frame portions. And a pair of pedestal portions 23 and 23 connected to the end portions of 21 and 22.

  The frame member 20 further includes a front locking portion 24 attached to each pedestal portion 23 and a rear locking portion 25 attached to the second frame portion 22. In the present embodiment, as the first and second frame portions 21 and 22 and the front and rear locking portions 24 and 25, for example, steel or aluminum wire (wire) having a diameter of about 3 to 6 mm is used. For example, it may be a metal strip-shaped or tubular steel material. Further, the frame material 20 may be manufactured from a steel plate by punching and press forming.

    The first frame portion 21 of the frame material 20 is disposed in the vicinity of the center of the front edge portion sF, and the second frame portion 22 includes both sides of the front edge portion sF, the right edge portion sR, and the left side. It is disposed in the vicinity of the edge portion sL, the rear edge portion sB, and each corner portion sC. The frame material 20 is embedded in a portion slightly inside from the outer peripheral surface 33 of the foamed resin molded body 30 forming the contour S so as to follow the contour S of the vehicle seat member 10.

  In this manner, the frame material 20 continuously circulates along the contour S of the vehicle seat member 10 by the first and second frame portions 21 and 22 and the pair of pedestal portions 23 and 23 connecting them. ing. In the present embodiment, the frame member 20 continuously circulates along the contour S of the vehicle seat member 10. For example, the frame member 20 extends along the contour S of the vehicle seat member 10. You may circulate intermittently. That is, not only in this form, the skeleton part may be arranged only in a part along the contour S. For example, the 2nd frame part 22 may be arrange | positioned along the back edge part sB, without being connected with the base parts 23 and 23. FIG. Further, the number of frame parts constituting the frame material 20 is not limited to two, and the number may be one or three or more.

  The front locking part 24 and the rear locking part 25 of the frame material 20 are parts for locking the vehicle seat member 10 to the vehicle. The front locking portion 24 is connected to the pedestal portion 23 by welding or adhesion, for example, and protrudes downward from the pedestal portion 23. The front end portion 24 a of the front locking portion 24 is curved in a substantially U shape, is exposed from the foamed resin molded body 30, and the base end portion 24 b is embedded in the foamed resin molded body 30 together with the pedestal portion 23. . More specifically, the entire base end portion 24 b is embedded in the foamed resin molded body 30. Thereby, even when a force in the pulling-out direction is applied when the vehicle seat member 10 of the present embodiment is locked to the vehicle via the distal end portion 24a of the front locking portion 24, the front locking portion 24 is applied. Is held by the foamed resin molded body 30 and can increase resistance to force in the pulling direction.

  Further, the rear locking portion 25 protrudes rearward from the central portion 22b along the rear edge portion sB in the second skeleton portion 22. The distal end portion 25 a of the rear locking portion 25 is curved in a substantially U shape, is exposed from the foamed resin molded body 30, and the base end portion 25 b is embedded in the foamed resin molded body 30.

  In this embodiment, the front end portions 24a and 25a of the front engaging portion 24 and the rear engaging portion 25 are formed by bending a wire rod into a substantially U shape, but the structure is not limited to this. What is necessary is just to make it the structure which can be latched according to a structure.

  In the present embodiment, the front locking portion 24 is connected to both the first and second frame portions 21 and 22 via the pedestal portion 23. However, the front locking portion 24 is not limited to this form, and is connected directly to both the first or second frame portions 21 and 22 without using the pedestal portion 23 like the rear locking portion 25. May be. Moreover, the number of the front latching | locking parts 24 is not specifically limited, One may be sufficient and three or more may be sufficient. One of the front locking part 24 and the rear locking part 25 may not exist.

1-2. About Foamed Resin Molded Body 30 As shown in FIGS. 1 and 2, the foamed resin molded body 30 is an in-mold foamed resin molded body of foamed resin. The foamed resin is not particularly limited, but usually, a foamed thermoplastic resin is used. Preferably used. The expansion ratio can be appropriately adjusted according to the type of the foamed resin, but is generally about 10 to 50 times, typically about 20 to 40 times.

  The foamed resin molded body 30 is formed with an upper surface 31 on the side on which a vehicle occupant sits and a bottom surface 32 on the side fastened to the vehicle. The foamed resin molded body 30 includes a frame-shaped portion 35 that embeds the frame material 20 and forms the outline S of the vehicle seat member 10 in a plan view of the vehicle seat member 10. The frame-shaped portion 35 includes a front portion 35a positioned in front of the seat and a rear portion 35b formed integrally with the front portion 35a and inclined rearward with the vehicle seat member 10 attached. It is configured. When the vehicle seat member 10 is incorporated in a vehicle, the front portion 35a of the foamed resin molded body 30 supports the upper leg portion of the occupant and the rear portion 35b supports the heel portion of the occupant.

  Specifically, as shown in FIG. 4, the upper surface 31 of the foamed resin molded body 30 is a curved surface that is recessed downward so that the vicinity of the rear end of the front portion 35 a is the deepest portion in the illustrated embodiment. Thus, the upper leg member 50 is formed so as to hold the occupant's upper leg and buttocks. However, the shape and thickness of the foamed resin molded body 30 can be variously changed depending on the shape of the vehicle main body side to which the vehicle seat member 10 is attached, and is not limited to the illustrated embodiment. For example, the upper surface 31 of the foamed resin molded body 30 may have a substantially flat shape.

  The foamed resin molded body 30 includes an extending portion 36 that extends from the frame-shaped portion 35 to the inside thereof so as to pass through the frame-shaped portion 35 inside the frame-shaped portion 35. More specifically, in the present embodiment, the frame member 20 has a second frame portion 22 (continuous portion) in which opposed portions 22a and 22a facing each other across the space inside the frame-shaped portion 35 are continuous. ing. The extending portion 36 is formed so as to extend between the facing portions 22a and 22a.

  Such an extended portion 36 is a reinforcing portion that reinforces the vehicle seat member 10, and by forming the extended portion 36 in the space inside the frame-shaped portion 35, the front portion 35 a of the foamed resin molded body 30 and In the rear portion 35b, there are formed thinned portions 38a and 38b, respectively. The lightening portions 38a and 38b reduce the weight of the foamed resin molded body 30, and other members constituting the vehicle seat (for example, cushion materials that are more easily elastically deformed than the foamed resin molded body 30, members of console boxes, etc. ) For the purpose of accommodating.

  As shown in FIGS. 1 to 3, the extending portion 36 of the foamed resin molded body 30 has a density (large specific gravity) larger than the density of the foamed resin molded body 30 in a direction to suppress deformation of the extending portion 36 due to heat. A weight 37 is attached. In the present embodiment, the weight 37 is exposed on the bottom surface 32 side of the foamed resin molded body 30. Examples of the weight 37 include metal materials such as aluminum or steel, ceramics, non-foamed resin, and the like.

  More specifically, in the present embodiment, the extending direction L in which the extending portion 36 extends coincides with the longitudinal direction of the vehicle seat member 10 and foaming is performed in a state where the weight 37 is not attached. When heat locally acts on the resin molded body 30, the extending portion 36 is deformed so as to bend upward at the center thereof. Therefore, in the present embodiment, the weight 37 is attached to the center of the extending portion 36 along the longitudinal direction. Furthermore, in the present embodiment, one weight 37 is formed along the longitudinal direction. However, for example, a plurality of attachment portions for attaching weights, for example, are provided on the extension portion 36, and a plurality of attachment portions are provided as necessary. A weight may be attached to the selected one or more attachments.

  Here, when heat is locally input to the vehicle seat member 10 during use (or when the input heat is dissipated), the frame material 20 of the foamed resin molded body 30 is embedded. The apparent amount of thermal expansion (heat shrinkage) differs between the frame-like portion 35 in the state and the extended portion 36 that extends inside the frame-like portion 35 and does not have the frame material 20. As a result, the extension portion 36 surrounded by the frame-like portion 35 is subjected to compressive stress and tensile stress as the thermal stress in a non-uniform manner, and in this embodiment, the extension portion 36 is deformed so as to curve upward. Easy to do. In particular, such a phenomenon is remarkable in the extending portion 36 formed along the longitudinal direction.

  However, in the present embodiment, the weight 37 is attached to the center of the extending portion 36 extending inside the frame-shaped portion 35 in a direction to suppress the deformation of the extending portion 36 due to heat. It is possible to suppress deformation of the extending portion 36 due to heat by its own weight. Thereby, even if the extension part 36 is thermally expanded and contracted, the dimensional accuracy of the vehicle seat member 10 can be ensured.

  In particular, in the present embodiment, a structure in which both sides of the extending portion 36 are constrained in the portion of the frame-like portion 35 in which the second framework portion 22 is embedded is adopted. For this reason, the extending part 36 is particularly easily deformed by thermal expansion and thermal contraction. When the frame material 20 continuously circulates along the contour S of the vehicle seat member 10, the extending portion 36 is further easily deformed. Even in such a case, in this embodiment, as described above, by attaching the weight 37 to the extending portion 36, the deformation of the extending portion 36 can be more effectively suppressed by the weight of the weight 37. it can.

2. About the manufacturing method of the vehicle seat member 10 The manufacturing method of the vehicle seat member 10 is demonstrated below, referring FIG. 5 and FIG. In FIG. 5, the frame material 20 and the weight 37 are indicated by solid lines for convenience. As shown in FIG. 5, when manufacturing the vehicle seat member 10 of the present embodiment, the frame material 20 and the weight 37 are arranged so as to be positioned in the cavity 73 of the mold 7. Next, after filling the pre-expanded resin particles 30A obtained by pre-expanding the expandable resin particles containing the resin and the foaming agent, the pre-expanded resin particles 30A are expanded by supplying steam into the mold 7 and expanded. The resin molded body 30 is molded. Thereafter, after cooling the foamed resin molded body 30 in the mold 7, the foamed resin molded body 30 is removed from the mold 7 together with the frame material 20, and the residual heat of the foamed resin molded body 30 is radiated (cooled). .

  By the way, the foamed resin molded body 30 has a property of shrinking slightly when the residual heat at the time of foam molding is dissipated after demolding. On the other hand, the frame material 20 made of a material such as metal has no substantial dimensional change compared to the foamed resin molded body 30 before and after the molding of the foamed resin molded body 30. Therefore, as shown in FIG. 7A, the foamed resin molded body 30 is molded with the molding die 7 including the first die 71 and the second die 72, and as shown in FIG. Until the foamed resin molded body 30 is demolded and the residual heat of the foamed resin molded body 30 is dissipated, the foamed resin molded body 30 is thermally contracted. At this time, since both sides of the extending portion 36 where the frame material 20 does not exist are restrained by the frame-like portion 35 where the frame material 20 exists, the extending portion 36 is not subjected to compressive stress or tensile stress as thermal stress. In this embodiment, for example, the extending portion 36 is easily deformed so as to bend upward from the center. And the deformation | transformation state of the foamed resin molding 30 immediately after shaping | molding will be hold | maintained after heat dissipation.

  In view of such points, in the present embodiment, the vehicle seat member 10 is manufactured as follows. First, the frame material 20 is prepared. The structure and material of the frame material 20 are as described above. Next, as shown in FIG. 5, the frame material 20 is placed in the mold 7 so that the frame material 20 is arranged along the contour S of the vehicle seat member 10 in a plan view of the vehicle seat member 10. Arrange (arrangement process). Further, in this arrangement step, the weight 37 is arranged in the mold 7 so that the weight 37 having a density larger than the density of the foamed resin molded body 30 is arranged in the extending portion 36. If necessary, the weight 37 may be fixed to the second mold 72 of the mold 7 with an adhesive tape or the like.

  As shown in FIGS. 5 and 6A, the molding die 7 includes a first die 71 and a second die 72, and when the first die 71 and the second die 72 are clamped, In addition, a cavity 73 corresponding to the foamed resin molded body 30 is formed.

  Next, as shown in FIG. 6A, after the first mold 71 and the second mold 72 in which the frame material 20 is arranged are temporarily clamped (cracked), the foamability including a resin and a foaming agent is included. The pre-foamed resin particles 30A obtained by pre-foaming the resin particles are filled and clamped.

  Next, as shown in FIG. 6 (b), the inside of the cavity 73 of the mold 7 is heated with steam or the like to secondary-foam the pre-foamed resin particles 30A, filling the gaps between the pre-foamed resin particles 30A, The pre-foamed resin particles 30A are integrated by fusing each other to form the foamed resin molded body 30 (molding step). Further, the frame material 20 and the weight 37 are integrated with the foamed resin molded body 30.

  In this manner, the foamed resin molded body 30 including the frame-shaped portion 35 and the extending portion 36 can be molded in the mold 7. The molded frame portion 35 embeds the frame material 20 and forms the contour S of the vehicle seat member 10. Further, the formed extending portion 36 extends inward from the frame-like portion 35 so as to pass the frame-like portion 35 inside the frame-like portion 35, and a weight 37 is attached to the extending portion 36.

  Next, the foamed resin molded body 30 in the mold 7 is cooled by water cooling or standing to cool. Furthermore, as shown in FIG.6 (c), the foaming resin molding 30 is demolded from the shaping | molding die 7, and the heat which remained in the foaming resin molding 30 after shaping | molding is thermally radiated (heat dissipation process). In this embodiment, after removing the foamed resin molded body 30 from the mold, while maintaining the posture of the foamed resin molded body 30 in a direction to suppress the deformation due to the thermal contraction of the extending portion 36 by the weight of the weight 37, The foamed resin molded body 30 is dissipated.

  Until now, as shown in FIG. 7B, the foamed resin molded body 30 is deformed so as to be curved upward due to the thermal contraction of the extending portion 36. However, after the foamed resin molded body 30 is removed from the mold 7, the posture of the foamed resin molded body 30 (upper surface) is adjusted in a direction that suppresses the upper curved deformation due to the thermal contraction of the extending portion 36 due to the weight of the weight 37. The foamed resin molded body 30 is dissipated while maintaining the position 31 on the upper side and the bottom surface 32 on the lower side.

  As a result, after removing the foamed resin molded body 30 from the middle of the mold 7, the residual heat after molding is dissipated, so that even if the foamed resin molded body 30 is thermally contracted, the thermal contraction is caused. The above-described deformation of the extended portion 36 can be suppressed by the weight of the weight 37. As a result, the vehicle seat member 10 with high dimensional accuracy can be manufactured.

  In the present embodiment, as shown in FIG. 5, the frame material 20 has a second frame portion 22, and the second frame portion 22 is opposed to each other with a space inside the frame-shaped portion 35 interposed therebetween. 22a and 22a have a continuous part which continued. When the foamed resin molded body 30 is molded, the extending portion 36 is formed so as to extend between the facing portions 22a and 22a. Therefore, since both sides of the extended portion 36 are originally restrained by the portion of the frame-like portion 35 in which the second frame portion 22 of the frame material 20 is embedded, the extended portion 36 is easily deformed by thermal contraction. . In particular, since the frame member 20 is continuously circulated along the contour S of the vehicle seat member 10, such deformation is likely to occur. Even in such a case, in the present embodiment, the extending portion 36 is provided with the weight 37 in a direction in which the deformation of the extending portion 36 due to heat is suppressed, so the deformation of the extending portion 36 is caused by the weight of the weight 37. Can be suppressed more effectively.

Second Embodiment
Hereinafter, a vehicle seat member 10 and a method for manufacturing the same according to a second embodiment of the present invention will be described with reference to FIG. The same configurations as those of the first embodiment are denoted by the same reference numerals and detailed description thereof is omitted. In the present embodiment, the weight 37 </ b> A is a magnetic body, and a magnet 74 that fixes the weight 37 </ b> A in the mold 7 is attached to the second mold 72 of the mold 7.

  Specifically, the magnet 74 is attached to the second mold 72, and the weight 37 </ b> A is fixed by attracting the weight 37 </ b> A to the magnet 74 by the magnetic force of the magnet 74. In the present embodiment, the periphery of the lower surface of the weight 37A is left and the magnet 74 is attracted to the center of the lower surface.

  Thus, as shown in FIG. 8 (a), the weight 37A can be fixed in the cavity of the mold 7 by the magnet 74. Therefore, when the pre-foamed resin particles 30A are filled and the mold is clamped, 37A can be prevented from being displaced. Further, when removing the foamed resin molded body 30 from the mold 7, the weight 37 </ b> A can be easily pulled away from the second mold 72. Further, in the present embodiment, as shown in FIG. 8C, the periphery of the lower surface of the weight 37A is left and the magnet 74 is attracted to the center of the lower surface, so that the periphery of the lower surface of the weight 37A is surrounded. Since the foamed resin molded body 30 is formed, the weight 37A can be more reliably avoided from falling off the foamed resin molded body 30.

<Third Embodiment>
Hereinafter, a vehicle seat member 10 and a method for manufacturing the same according to a third embodiment of the present invention will be described with reference to FIG. The same configurations as those of the first embodiment are denoted by the same reference numerals and detailed description thereof is omitted. In the present embodiment, as shown in FIG. 9A, the weight 37B is formed with a protruding portion 37b protruding from the side surface.

  Accordingly, as shown in FIG. 9B, the weight 37B is formed integrally with the foamed resin molded body 30, and as shown in FIG. 9B, the protruding portion 37b of the weight 37B is formed into the foamed resin molded body. Therefore, the weight 37 </ b> B can be more reliably avoided from falling off the foamed resin molded body 30.

<Other embodiments>
Hereinafter, other embodiments of the present invention will be described with reference to FIGS. Note that, among the configurations of the vehicle seat member 10 according to these other embodiments, configurations common to the first embodiment and the second embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 10, in this embodiment, the extending portion 36 of the vehicle seat member 10 includes a first extending portion 36A extending in the longitudinal direction and two second extending portions extending in the short direction. Existing portions 36B, 36B. 36 A of 1st extension parts and the 2nd extension part 36B are connected by the connection part 36C. In the present embodiment, a weight 37C is also attached to each second extending portion 36B. Due to the dead weight of the weight 37C, deformation of the second extending portion 36B during molding and use can be suppressed.

  Thus, by providing the first extending portion 36 </ b> A and the second extending portion 36 </ b> B that intersect each other inside the frame-shaped portion 35, the vehicle seat member 10 can be reinforced. Further, by arranging the weights 37 and 37C in both the first extension portion 36A and the second extension portion 36B, the first extension portion 36A and the second extension portion 36B in use at their own weight. It is possible to suppress thermal deformation such as bending. Furthermore, the deformation of the first extending portion 36A and the second extending portion 36B, which is caused by the thermal shrinkage of the foamed resin molded body 30 after the mold removal, can be suppressed.

  In the present embodiment shown in FIG. 10, the frame member 20 continuously circulates along the contour S of the vehicle seat member 10, but the frame member 20 extends along the contour S of the vehicle seat member 10. It suffices if it is arranged at least in part. Therefore, as shown in FIG. 11, the second frame portion 22 may not be connected to the pedestal portions 23 and 23 but may be disposed only along the rear edge portion sB.

  Furthermore, as shown in FIG. 12, a frame having a second frame portion 22 (continuous portion) in which the opposing portions 22a, 22a facing each other across the space inside the frame-like portion 35 are continuous. Material 20 may be used.

  As mentioned above, although some embodiment of this invention was explained in full detail, this invention is not limited to the said embodiment, In the range which does not deviate from the mind of this invention described in the claim, Various design changes can be made.

1: vehicle seat, 7: molding die, 10: vehicle seat member, 20: frame material, 21: first frame portion, 22: second frame portion (continuous portion), 22a: facing portion, 30: foamed resin Molded body, 35: frame-like portion, 36: extending portion, 36A: first extending portion, 36B: second extending portion, 37, 37A, 37B, 37C: weight

Claims (9)

A method for manufacturing a vehicle seat member comprising a frame material and a foamed resin molded body in which the frame material is embedded,
An arrangement step of arranging the frame material in a mold so that the frame material is arranged along an outline of the vehicle seat member in a plan view of the vehicle seat member;
In the mold, the frame material is embedded and the contour of the vehicle seat member is formed, and the frame-shaped portion extends inward from the frame-shaped portion so as to extend inside the frame-shaped portion. A molding step for molding a foamed resin molded body including the extending portion,
Removing the foamed resin molded body from the mold, and radiating heat remaining in the foamed resin molded body after molding,
In the placing step, the weight is placed in the mold together with the frame material so that a weight having a density larger than the density of the foamed resin molded body is placed in the extending portion.
In the heat dissipation step, after removing the foamed resin molded body at least, the foamed resin molded body is maintained while maintaining the posture of the foamed resin molded body in a direction to suppress deformation due to thermal contraction of the extending portion by the weight of the weight. A method of manufacturing a vehicle seat member, wherein the heat of the resin molded body is dissipated. The frame material has a continuous portion in which opposed portions facing each other across the space inside the frame-shaped portion are continuous,
The method for manufacturing a vehicle seat member according to claim 1, wherein in the molding step, the extending portion is molded so as to extend between the opposing portions. The outline of the vehicle seat member in the plan view is a shape having a short direction and a long direction,
In the forming step, the extending part is formed so as to include at least a first extending part extending along the longitudinal direction across the opposing part of the frame-like part,
3. The method of manufacturing a vehicle seat member according to claim 1, wherein, in the arranging step, the weight is arranged at a position where the first extending portion is molded. The weight is a magnetic body, and a magnet for fixing the weight in the molded body with a magnetic force is attached to the mold.
The method for manufacturing a vehicle seat member according to any one of claims 1 to 3, wherein the weight is fixed to the magnet in the arranging step.   The method for manufacturing a vehicle seat member according to any one of claims 1 to 4, wherein the frame member is circulated along an outline of the vehicle seat member. A vehicle seat member comprising a frame material and a foamed resin molded body in which the frame material is embedded,
The frame material is arranged along an outline of the vehicle seat member in a plan view of the vehicle seat member,
The foamed resin molded body includes a frame-shaped portion that embeds the frame material and forms an outline of the vehicle seat member, and an inner side from the frame-shaped portion so as to pass the frame-shaped portion inside the frame-shaped portion. And an extending portion extending to
A vehicular seat member, wherein a weight having a density larger than the density of the foamed resin molded body is attached to the extending portion at a position where deformation of the extending portion due to heat is suppressed.   The frame material has a continuous portion in which opposed portions facing each other across a space inside the frame-shaped portion are continuous, and the extending portion is formed to extend between the opposed portions. The vehicle seat member according to claim 6, wherein the vehicle seat member is provided. The outline of the vehicle seat member in the plan view is a shape having a short direction and a long direction,
The extension part includes a first extension part along the longitudinal direction over the opposing part of the frame-like part,
The vehicle seat member according to claim 6 or 7, wherein the weight is attached to the first extending portion.   The vehicle frame member according to any one of claims 6 to 8, wherein the frame member circulates along an outline of the vehicle seat member.

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