JP2018134360A

JP2018134360A - Seat pad for vehicle

Info

Publication number: JP2018134360A
Application number: JP2017032923A
Authority: JP
Inventors: 佳宏犬飼; Yoshihiro Inukai
Original assignee: Inoue MTP KK; Inoac Corp
Current assignee: Inoac Corp
Priority date: 2017-02-24
Filing date: 2017-02-24
Publication date: 2018-08-30
Anticipated expiration: 2037-02-24
Also published as: JP6847707B2

Abstract

【課題】ビーズ発泡成形品を採用しながら、車両へのシートパッドの組付け不良を起こさず、安定生産維持を図って、大胆な軽量化が実現できる車両用シートパッドを提供する。【解決手段】少なくとも乗員が当接する側の当たり面部分を軟質ポリウレタン発泡成形体で形成した車両用シートパッドにおいて、ビーズ発泡成形体の主部2Aを主構成にして環状に成形されている外芯体2と、該外芯体2のビーズ発泡成形体よりも発泡倍率を高くしたビーズ発泡成形体からなり、該外芯体2の環状内に配される内芯体3と、前記外芯体2とその環状内に配した内芯体3とを埋設一体化している軟質ポリウレタン発泡成形体にして、意匠面4a側に前記当たり面部分41を有する表層パッド4と、を具備する。【選択図】図１PROBLEM TO BE SOLVED: To provide a vehicle seat pad capable of realizing a bold weight reduction while maintaining stable production without causing a failure in assembling the seat pad to a vehicle while adopting a bead foam molded product. SOLUTION: In a vehicle seat pad in which at least a contact surface portion on a side where an occupant comes into contact is formed of a flexible polyurethane foam molded body, an outer core formed in an annular shape with a main portion 2A of the bead foam molded body as a main configuration. The body 2 is composed of a bead-foamed molded product having a higher foaming ratio than the bead-foamed molded product of the outer core body 2, and the inner core body 3 arranged in the ring of the outer core body 2 and the outer core body. A flexible polyurethane foam molded body in which 2 and an inner core body 3 arranged in an annular shape thereof are embedded and integrated, and a surface pad 4 having the contact surface portion 41 on the design surface 4a side is provided. [Selection diagram] Fig. 1

Description

本発明は、車両用座席シートを構成するクッションパッドやバックパッドの車両用シートパッドに関する。 The present invention relates to a vehicle seat pad such as a cushion pad or a back pad constituting a vehicle seat.

自動車等の車両に搭載される座席シートで、クッションパッドやバックパッドのシートパッドは、従来、快適なクッション性が得られるよう軟質ポリウレタン発泡体で造られてきた。ただ、近年になり、一部をビーズ発泡成形体に担わせて、車両の軽量化に応える動きがある。ビーズ発泡成形体の芯パッドをインサート品にして、軟質ポリウレタン発泡成形体の表層パッドを一体発泡成形したシートパッドの発明が提案されるようになっている（例えば特許文献１）。 In the seats mounted on vehicles such as automobiles, cushion pads and seat pads for back pads have been conventionally made of a flexible polyurethane foam so as to obtain a comfortable cushioning property. However, in recent years, there is a movement to respond to the weight reduction of vehicles by placing a part on the bead foam molding. There has been proposed an invention of a seat pad in which a core pad of a bead foam molded body is an insert product and a surface layer pad of a soft polyurethane foam molded body is integrally foam molded (for example, Patent Document 1).

特許第５２７７９１２号公報Japanese Patent No. 5277912

しかるに、特許文献１は、その請求項１が「…裏層パッドは、表側前後左右外周に沿って形成されかつ前記凹部に突入する凸部と、中央に形成され且つ前記膨出部が突入される穴と、前記表皮の端末が係止される係止部とを有する」発明であり、シートクッションのなかで、軽量化の役目を担うビーズ発泡成形体たる裏層パッドの占める割合が小さい。また、乗物ボディに取付けられ得る取付部を裏層パッドに設けるが、より軽量化を目指して裏層パッドの発泡倍率を上げようとすると、寸法精度が悪くなり、取付部を使っての乗物ボディへの取付けが難しくなる。
特に、発泡ポリプロピレン(ＥＰＰ),発泡ポリスチロール(ＥＰＳ)等のビーズ発泡成形体は、発泡倍率が上がると寸法精度が悪くなる。例えばシートパッドの軽量化で検討が進むＥＰＰのビーズ発泡成形品では、寸法精度を良好維持できる発泡倍率として25倍を設定すると密度が約0.040g/cm^３になって、シートパッド用軟質ポリウレタン発泡成形体の密度0.045g/cm^３と殆ど変わらない。軽量化があまり期待できない。
軽量化を目指して発泡倍率が30倍程度を採用したいが、そうすると、出来上がったビーズ発泡成形品がひねったり反ったりする不具合がでる。該ビーズ発泡成形成形品をシートパッド用成形型にセットした際、ビーズ発泡成形品の一部が型面から浮き上がり、軟質ポリウレタン発泡成形品の発泡成形に支障をきたす。また、ビーズ発泡成形品へ、車両に取付けるためのＵ字形フックを埋設一体化するケースを考えると、取付基準となるＵ字形フックに誤差がでると、車両へのシートパッドの組付け不良問題が発生する。 However, Patent Document 1 discloses that claim 1 is that “... the back layer pad is formed along the front side, front, rear, left and right outer periphery and protrudes into the recess, and is formed in the center and the bulge is inserted. The back layer pad, which is a bead foam molded body that plays a role in weight reduction, is small in the seat cushion. In addition, a mounting part that can be attached to the vehicle body is provided on the back layer pad. However, if the foaming ratio of the back layer pad is increased to reduce the weight, the dimensional accuracy deteriorates and the vehicle body using the mounting part is used. It becomes difficult to attach to.
In particular, bead foam moldings such as expanded polypropylene (EPP) and expanded polystyrene (EPS) have poor dimensional accuracy when the expansion ratio is increased. For example, with EPP bead foam molded products, which are being studied for weight reduction of seat pads, the density becomes approximately 0.040 g / cm ³ when a foaming magnification of 25 times is set to maintain good dimensional accuracy. The density of the molded body is almost the same as 0.045 g / cm ³ . We cannot expect much weight reduction.
We want to adopt a foaming ratio of about 30 times with the aim of reducing weight, but doing so will cause the resulting bead foam molding to twist or warp. When the bead foam-molded product is set in a seat pad mold, a part of the bead foam-molded product is lifted from the mold surface, which hinders foam molding of a soft polyurethane foam-molded product. Also, considering the case in which a U-shaped hook for mounting on a vehicle is embedded in a bead foam molded product, if there is an error in the U-shaped hook serving as a reference for mounting, there is a problem of poor seat pad assembly on the vehicle. Occur.

本発明は、上記問題を解決するもので、ビーズ発泡成形品を採用しながら、車両へのシートパッドの組付け不良を起こさず、安定生産維持を図って、大胆な軽量化が実現できる車両用シートパッドを提供することを目的とする。 The present invention solves the above-described problem. For a vehicle that can realize a bold weight reduction by adopting a bead foam molded product, without causing a defective assembly of a seat pad to the vehicle, and maintaining stable production. An object is to provide a seat pad.

上記目的を達成すべく、請求項１に記載の発明の要旨は、少なくとも乗員が当接する側の当たり面部分を軟質ポリウレタン発泡成形体で形成した車両用シートパッドにおいて、ビーズ発泡成形体の主部を主構成にして環状に成形されている外芯体と、該外芯体のビーズ発泡成形体よりも発泡倍率を高くしたビーズ発泡成形体からなり、該外芯体の環状内に配される内芯体と、前記外芯体とその環状内に配した内芯体とを埋設一体化している軟質ポリウレタン発泡成形体にして、意匠面側に前記当たり面部分を有する表層パッドと、を具備することを特徴とする車両用シートパッドにある。
請求項２の発明たる車両用シートパッドは、請求項１で、外芯体は、車両取付け具がインサートされて前記主部が成形されていることを特徴とする。請求項３の発明たる車両用シートパッドは、請求項１又は２で、外芯体の裏面に、表皮端部の固定用溝が形成されていることを特徴とする。請求項４の発明たる車両用シートパッドは、請求項２又は３で、外芯体に、前記車両取付け具が接続する環状ワイヤが埋設されていることを特徴とする。請求項５の発明たる車両用シートパッドは、請求項１〜４で、外芯体とその環状内に配設した内芯体との間に隙間が設けられ、該隙間が前記表層パッドに係る軟質ポリウレタン発泡成形部で埋められていることを特徴とする。 In order to achieve the above object, the gist of the invention described in claim 1 is that the main part of the bead foam molded body is a vehicle seat pad in which at least the contact surface portion on the side where the passenger abuts is formed of a soft polyurethane foam molded body. And a bead foam molded body having a higher expansion ratio than the bead foam molded body of the outer core body, and is arranged in the annular shape of the outer core body. An inner core body, and a soft polyurethane foam molded body in which the outer core body and the inner core body arranged in the ring are embedded and integrated, and a surface layer pad having the contact surface portion on the design surface side. The vehicle seat pad is characterized by the following.
A vehicle seat pad according to a second aspect of the present invention is the vehicle seat pad according to the first aspect, wherein the outer core has the main portion formed by inserting a vehicle fixture. A vehicle seat pad according to a third aspect of the present invention is the vehicle seat pad according to the first or second aspect, characterized in that a fixing groove at an end portion of the skin is formed on the back surface of the outer core body. A vehicle seat pad according to a fourth aspect of the present invention is the vehicle seat pad according to the second or third aspect, wherein an annular wire connected to the vehicle mounting tool is embedded in the outer core body. A vehicle seat pad according to a fifth aspect of the present invention is the vehicle seat pad according to the first to fourth aspects, wherein a gap is provided between the outer core body and the inner core body disposed in the annular shape, and the gap relates to the surface layer pad. It is filled with a soft polyurethane foam molded part.

本発明の車両用シートパッドは、ビーズ発泡成形品を採用しながら車両への組付け精度を確保して取付け不良を起こさず、歩留まり向上を図ると同時に、大幅な軽量化が達成できるなど優れた効果を発揮する。 The vehicle seat pad of the present invention is excellent in that it can achieve a significant weight reduction while improving the yield without securing a mounting failure by ensuring the accuracy of assembly to the vehicle while adopting a bead foam molded product. Demonstrate the effect.

本発明のシートパッドの一形態で、シートパッドを裏面側から見た斜視図である。It is the perspective view which looked at the seat pad from the back side in one form of the seat pad of the present invention. 図１のII-II線矢視図である。It is the II-II arrow directional view of FIG. 図２に代わる図１のII-II線矢視図である。It is the II-II arrow directional view of FIG. 1 replaced with FIG.

以下、本発明に係る車両用シートパッド（以下、単に「シートパッド」ともいう。）について詳述する。図１〜図３は本発明のシートパッドの一形態で、クッションパッドに適用する。図１はシートパッドを裏面側から見た斜視図、図２は図１のII-II線矢視図、図３は図２に代わる図１のII-II線矢視図を示す。シートパッドの裏面側を表す図１は紙面上方がシートパッドの車両前方で、図２は車両設置の姿態にしたシートパッドの断面図であり、紙面左方が車両前方になる。各図は図面を判り易くするため簡略図示し、また本発明と直接関係しない部分を省略する。 Hereinafter, a vehicle seat pad (hereinafter also simply referred to as “seat pad”) according to the present invention will be described in detail. 1 to 3 show an embodiment of a seat pad according to the present invention, which is applied to a cushion pad. 1 is a perspective view of the seat pad as viewed from the back side, FIG. 2 is a view taken along the line II-II in FIG. 1, and FIG. 3 is a view taken along the line II-II in FIG. In FIG. 1 showing the back side of the seat pad, the upper side of the sheet is the front of the vehicle with the seat pad, FIG. Each figure is simplified for easy understanding of the drawings, and portions not directly related to the present invention are omitted.

車両用シートパッド１は乗員が当接する側が意匠面４ａとなる。車両用シートパッド１は、外芯体２と内芯体３と表層パッド４とを具備し、少なくとも乗員が当接する側の当たり面部分４１が表層パッド４の軟質ポリウレタン発泡成形体で形成されている。
外芯体２は、ビーズ発泡成形体を主構成にして環状成形された軽量ブロックである。ここでの外芯体２は、発泡ポリプロピレン(ＥＰＰ)のビーズ発泡成形体で、軽量といっても必要な寸法精度を確保すべく発泡倍率を25倍程度の低発泡倍率に抑え、密度が0.040g/cm^３程度になっている。軟質ポリウレタン発泡成形体で形成された表層パッド４の密度0.045g/cm^３より少しだけ軽い。外芯体２の寸法精度を良好にして、シートパッド１の発泡成形型に外芯体２を保持させてセットするのを容易にする。外芯体２の発泡成形で組み込まれる車両取付け具たるＵ字形フック２Ｂによるシートパッド１の車両への取付け精度を上げている。図１,図２のごとく、シートパッド１の外周沿いに該外周よりもやや小さめの外周面２４を有し、且つ内周面２３内の突抜け穴２０を大きくくり抜いたドーナツ形の環状ブロックで外芯体２の主部２Ａを構成する。シートパッド１の成形に先立ち、予めＵ字形フック２Ｂをインサート品にして該主部２Ａをビーズ発泡成形し、外芯体２を得る。車両取付け具のＵ字形フック２Ｂがインサートされてビーズ発泡成形体からなる主部２Ａが成形されている。Ｕ字形フック２Ｂは、頭部分が露出するようにして主部２Ａに埋設一体化する。 The vehicle seat pad 1 has a design surface 4a on the side where the occupant abuts. The vehicle seat pad 1 includes an outer core body 2, an inner core body 3, and a surface layer pad 4, and at least a contact surface portion 41 on the side where an occupant abuts is formed of a soft polyurethane foam molded body of the surface layer pad 4. Yes.
The outer core body 2 is a lightweight block that is annularly molded with a bead foam molded body as a main component. The outer core body 2 is a foamed foamed polypropylene (EPP) bead foam molded body, and although the weight is small, the foaming ratio is suppressed to a low foaming ratio of about 25 times to ensure the necessary dimensional accuracy, and the density is 0.040. It has become the order of g / cm ^3. It is slightly lighter than the density of 0.045 g / cm ³ of the surface layer pad 4 formed of a flexible polyurethane foam molding. The dimensional accuracy of the outer core body 2 is improved, and the outer core body 2 is easily held and set in the foaming mold of the seat pad 1. The mounting accuracy of the seat pad 1 to the vehicle by the U-shaped hook 2B, which is a vehicle mounting tool incorporated by foam molding of the outer core body 2, is increased. As shown in FIGS. 1 and 2, the outer peripheral surface 24 is slightly smaller than the outer periphery along the outer periphery of the seat pad 1, and a donut-shaped annular block in which the through hole 20 in the inner peripheral surface 23 is greatly hollowed out. A main portion 2A of the core body 2 is configured. Prior to molding of the seat pad 1, the U-shaped hook 2B is used as an insert product in advance to form the main portion 2A by bead foam molding to obtain the outer core body 2. A U-shaped hook 2B of a vehicle fixture is inserted to form a main portion 2A made of a bead foam molded body. The U-shaped hook 2B is embedded and integrated in the main portion 2A so that the head portion is exposed.

ここで、本発明でいう「ビーズ発泡成形体」とは、いわゆるビーズ発泡法によって得られた発泡成形体で、原料ビーズを予備発泡成形させた後、型内発泡成形によって成形されている発泡成形体をいう。外芯体２や内芯体３のようなブロック状の発泡成形体である。ビーズ発泡法は単にビーズ法ともいう。ビーズ発泡成形体は、発泡ポリプロピレン、発泡スチロール、発泡ポリエチレン、又はこれらのうち一つを少なくとも含む成形体であるのが好ましい。気泡が内部に密閉されたビーズ発泡成形体となっており、且つ体積の大部分が気体で軽量にして、発泡倍率を上げることによって、その密度をシートパッド１用の軟質ポリウレタン発泡成形体の密度よりも小さくできる。発泡ポリプロピレンからなるビーズ発泡成形体は、耐熱性に優れており、車両用シートパッド１としてより好ましい。 Here, the “bead foam molded product” referred to in the present invention is a foam molded product obtained by a so-called bead foaming method, in which raw material beads are pre-foamed and then molded by in-mold foam molding. Refers to the body. It is a block-like foamed molded body such as the outer core body 2 and the inner core body 3. The bead foaming method is also simply called a bead method. The bead foam molded body is preferably foamed polypropylene, foamed polystyrene, foamed polyethylene, or a molded body containing at least one of them. It is a bead foam molded body with air bubbles sealed inside, and the bulk of the volume is made of gas and light weight, and the density is increased by increasing the foaming ratio. Can be smaller. A bead foam molded body made of expanded polypropylene is excellent in heat resistance and is more preferable as the vehicle seat pad 1.

本実施形態は、さらにＵ字形フック２Ｂが接続する環状ワイヤ２Ｃが外芯体２に埋設されている。環状ワイヤ２Ｃは、突抜け穴２０よりも一回り大きなリング形状にして、環状に成形された主部２Ａの断面内部に配され、図２のごとく主部２Ａの環状に沿う形で埋設一体化される。Ｕ字形フック２Ｂはその最も近い環状ワイヤ２Ｃの箇所に接続固定する。
また外芯体２の裏面２２には、図２のごとく表皮端部９１をシートパッド１に係止固定するための固定用溝２５が形成される。固定用溝２５は、シートパッド１の裏面で、図１のごとく外芯体２の下面側外周縁２４１に沿って所定間隔で複数設けられる。尚、シートパッド１の構成を判り易くするため、図２のような環状外芯体２を図示するが、外芯体２はシートパッド１でのＵ字形フック２Ｂや固定用溝２５の取付け位置精度を上げる目的のために、シートパッド１の軽量化を目指す内芯体３と分離させている。したがって、外芯体２は、これがシートパッド１に一体化した時にＵ字形フック２Ｂや固定用溝２５が所定の位置精度を確保できるなら、突抜け穴２０を図１,図２のものよりももっと大きくして、軽量化の役目を担う内芯体３の方をより大きくさせるのが好適となる。 In the present embodiment, an annular wire 2C to which the U-shaped hook 2B is further connected is embedded in the outer core body 2. The annular wire 2C is formed in a ring shape that is slightly larger than the punch-through hole 20 and is arranged inside the section of the annularly formed main portion 2A, and is embedded and integrated along the annular shape of the main portion 2A as shown in FIG. The The U-shaped hook 2B is connected and fixed to the nearest annular wire 2C.
Further, as shown in FIG. 2, a fixing groove 25 for locking and fixing the skin end portion 91 to the seat pad 1 is formed on the back surface 22 of the outer core body 2. A plurality of fixing grooves 25 are provided at predetermined intervals along the lower surface side outer peripheral edge 241 of the outer core body 2 as shown in FIG. In order to make the configuration of the seat pad 1 easy to understand, an annular outer core body 2 as shown in FIG. 2 is illustrated, but the outer core body 2 is attached to the seat pad 1 at the mounting position of the U-shaped hook 2B and the fixing groove 25. For the purpose of increasing accuracy, the seat pad 1 is separated from the inner core body 3 aiming at weight reduction. Therefore, if the outer core body 2 is integrated with the seat pad 1 and the U-shaped hook 2B and the fixing groove 25 can secure a predetermined positional accuracy, the through-hole 20 is formed more than the one shown in FIGS. It is preferable to increase the size of the inner core body 3 that plays the role of weight reduction.

内芯体３は、シートパッド１のほぼ中央下部に位置して、前記外芯体２の環状内に配されるビーズ発泡成形体の塊状ブロックである(図２)。内芯体３は前記外芯体２のビーズ発泡成形体の発泡倍率よりも発泡倍率を高くした高発泡倍率(例えば40倍)のビーズ発泡成形体であり、その密度を外芯体２に対し小さくしている。外芯体２の突抜け穴２０に、高発泡倍率の極めて軽い内芯体３を配して、シートパッド１のなかでも占有率の高い該内芯体３がシートパッド１の軽量化実現に向けて大きな役目を果たしている。
具体的には内芯体３の発泡倍率を40倍以上と大きくし、外芯体２はもとより表層パッド４よりも格段に密度を小さく軽くして、内芯体３でシートパッド１の軽量化が担えるように設定される。ＥＰＰで発泡倍率40倍とした本実施形態の内芯体３の密度は0.025g/cm^３程度になる。シートパッド１のなかで、内芯体３はできる限り大きな体積占有率を占めるように設定する共に、40倍以上の高発泡倍率に設定するのが望ましい。発泡倍率を40倍以上と大きくすることによって内芯体３の寸法精度は悪くなるが、本発明は寸法精度が必要とされるＵ字形フック２Ｂや固定用溝２５は外芯体２に依存させ、内芯体３は、シートパッド１中、寸法精度がさほど要求されない部位構成になっている。内芯体３は寸法精度が悪くなっても不都合ない。 The inner core body 3 is a block block of a bead foam molded body which is located in the lower part of the center of the seat pad 1 and is arranged in the annular shape of the outer core body 2 (FIG. 2). The inner core body 3 is a bead foam molded body having a high expansion ratio (for example, 40 times) that is higher than the expansion ratio of the bead foam molded body of the outer core body 2. It is small. An extremely light inner core body 3 with a high foaming ratio is arranged in the punch-through hole 20 of the outer core body 2, and the inner core body 3 having a high occupation ratio among the seat pads 1 is intended to realize the weight reduction of the seat pad 1. Plays a big role.
Specifically, the foaming ratio of the inner core body 3 is increased to 40 times or more, and the density of the outer core body 2 and the surface layer pad 4 is made much smaller and lighter. Is set to carry. The density of the inner core body 3 of this embodiment, which is 40 times the expansion ratio by EPP, is about 0.025 g / cm ³ . In the seat pad 1, the inner core body 3 is preferably set to occupy as large a volume occupation ratio as possible, and is preferably set to a high foaming ratio of 40 times or more. Although the dimensional accuracy of the inner core body 3 is deteriorated by increasing the expansion ratio to 40 times or more, the present invention makes the U-shaped hook 2B and the fixing groove 25 that require dimensional accuracy depend on the outer core body 2. In the seat pad 1, the inner core body 3 has a part configuration that does not require much dimensional accuracy. The inner core 3 is not inconvenient even if the dimensional accuracy is deteriorated.

本内芯体３は、図２のように表面３１側（ここでは上面側）が車両前方側で外芯体２の表面２１に合わせた高所面３１１を形成し、車両後方に向けてスロープ３１２を経て一段低くした低所面３１３を有するビーズ発泡成形体からなる軽量ブロックである。内芯体３の表面３１で位置ずれや変形を起こしても、その表面上方側には表層パッド４の当たり面部分４１が積層される。内芯体３をインサート品にして表層パッド４を発泡成形したシートパッド１となれば、表層パッド４における着座乗員の当たり面部分４１が内芯体３の変形をカバーして、良好なシートパッド１にできる。
また、内芯体３は外芯体２の環状内に配されることから、内芯体３が外周面３４側で位置ずれや変形を起こしても、外芯体２の突抜け穴２０に収まっていて不具合とならない。シートパッド１の変形として現れることがない。本実施形態は、図２のごとく外芯体２の突抜け穴２０よりも一回り外周面３４が小さな内芯体３である。内芯体３が、外芯体２に対し筒状隙間εを設けて離間状態で突抜け穴２０に収まり、且つ該隙間εは表層パッド４の軟質ポリウレタン発泡成形部４４で埋められている。したがって、内芯体３の外周面３４側での位置ずれや変形は、このクッション性のある軟質ポリウレタン発泡成形部４４が吸収する。
さらに、内芯体３が裏面３２側で位置ずれや変形を起こしても、問題になることもない。例えば、図１のシートパッド１は、正規状態で、II-II線矢視図で表す図２のごとく内芯体３と外芯体２の両裏面３２,２２が面一になるよう設定されている。万一、シートパッド１の発泡成形で、内芯体３の裏面側外周縁３４１が図３のごとく外芯体の裏面側内周縁２２１からずれて沈み込み、外芯体２との間に段差部７が発生するような製品になっても、シートパッド１が車両に設置された段階で隠れる部位であり、支障ない。図３では、表層パッド４の発泡成形で、内芯体３と外芯体２との筒状隙間εを通ってできた裏面側回り込み部分４８を図示するが、該回り込み部分４８はバリ状態であり、簡単に除去できる。また、通常、シートパッド１の裏面は図示しない不織布からなる裏面材で覆われるので、問題にならない。 As shown in FIG. 2, the inner core body 3 has a surface 31 side (here, the upper surface side) formed on the front side of the vehicle with a height surface 311 that matches the surface 21 of the outer core body 2, and slopes toward the rear of the vehicle. This is a lightweight block made of a bead foam molded body having a lower surface 313 that is lowered by 312. Even if displacement or deformation occurs on the surface 31 of the inner core body 3, the contact surface portion 41 of the surface layer pad 4 is laminated on the upper side of the surface. If the seat pad 1 is formed by foaming the surface pad 4 using the inner core body 3 as an insert product, the contact surface portion 41 of the seated occupant in the surface layer pad 4 covers the deformation of the inner core body 3 and is a good seat pad. Can be 1.
In addition, since the inner core body 3 is disposed in the annular shape of the outer core body 2, even if the inner core body 3 is displaced or deformed on the outer peripheral surface 34 side, the inner core body 3 is accommodated in the through hole 20 of the outer core body 2. It does not become a malfunction. It does not appear as a deformation of the seat pad 1. In the present embodiment, as shown in FIG. 2, the inner core body 3 has a smaller outer peripheral surface 34 than the punch-through hole 20 of the outer core body 2. The inner core body 3 is provided with a cylindrical gap ε with respect to the outer core body 2 and fits into the punch-through hole 20 in a separated state, and the gap ε is filled with the soft polyurethane foam molded portion 44 of the surface layer pad 4. Therefore, the positional shift and deformation on the outer peripheral surface 34 side of the inner core body 3 are absorbed by the soft polyurethane foam molded portion 44 having cushioning properties.
Furthermore, even if the inner core body 3 is displaced or deformed on the back surface 32 side, there is no problem. For example, the seat pad 1 in FIG. 1 is set in a normal state so that the back surfaces 32 and 22 of the inner core body 3 and the outer core body 2 are flush with each other as shown in FIG. ing. In the unlikely event that the seat pad 1 is foamed, the outer peripheral edge 341 of the inner core body 3 is displaced from the inner peripheral edge 221 of the outer core body as shown in FIG. Even if it becomes a product which the part 7 generate | occur | produces, it is a site | part hidden when the seat pad 1 is installed in the vehicle, and there is no problem. FIG. 3 illustrates a back side wraparound portion 48 formed through the cylindrical gap ε between the inner core body 3 and the outer core body 2 by foam molding of the surface layer pad 4. The wraparound portion 48 is in a burr state. Yes, it can be easily removed. Moreover, since the back surface of the seat pad 1 is usually covered with a back material made of a nonwoven fabric (not shown), there is no problem.

表層パッド４は、意匠面４ａ側に乗員が当接する側の当たり面部分４１を有して、外芯体２とその環状内に配した内芯体３とを埋設一体化している軟質ポリウレタン発泡成形体である。
本実施形態は、既述のごとく外芯体２と突抜け穴２０に配した内芯体３との間に筒状隙間εが設けられている。表層パッド４の発泡成形で、該隙間εが表層パッド４の一部を構成する軟質ポリウレタン発泡成形部４４で埋められたシートパッド１になっている。
シートパッド１は、その発泡成形型に前記内芯体３及び外芯体２をセットした後、軟質ポリウレタン発泡原料を注入すると共に型閉じし、表層パッド４が内芯体３,外芯体２と一体発泡成形されることによって得られる。シートパッド１は、その発泡成形型に外芯体２,内芯体３を保持しておいて、表層パッド４の一体発泡成形でできた複合製品である。表層パッド４の発泡成形過程で、着座乗員の当たり面部分４１やパッド側面４３の部位等と共に、発泡原料が内芯体３と外芯体２との筒状隙間εに浸入して、軟質ポリウレタン発泡成形部４４を形成し、内芯体３と外芯体２と表層パッド４とが一体化される。 The surface layer pad 4 has a contact surface portion 41 on the side where the occupant abuts on the design surface 4a side, and is a soft polyurethane foam in which the outer core body 2 and the inner core body 3 disposed in the ring are embedded and integrated. It is a molded body.
In the present embodiment, as described above, the cylindrical gap ε is provided between the outer core body 2 and the inner core body 3 disposed in the punch-through hole 20. In the foam molding of the surface layer pad 4, the gap ε is the seat pad 1 filled with the soft polyurethane foam molding part 44 constituting a part of the surface layer pad 4.
The seat pad 1 has the inner core body 3 and the outer core body 2 set in the foaming mold, and then the soft polyurethane foam raw material is injected and the mold is closed, and the surface layer pad 4 has the inner core body 3 and the outer core body 2. And obtained by integral foam molding. The seat pad 1 is a composite product made by integral foam molding of the surface layer pad 4 while holding the outer core body 2 and the inner core body 3 in the foam mold. In the foam molding process of the surface layer pad 4, the foaming raw material enters the cylindrical gap ε between the inner core body 3 and the outer core body 2 together with the contact surface portion 41 of the seated occupant and the portion of the pad side surface 43. The foam molded portion 44 is formed, and the inner core body 3, the outer core body 2, and the surface layer pad 4 are integrated.

ここで、前記外芯体２,内芯体３を構成するビーズ発泡成形体には、表層パッド４の軟質ポリウレタン成形体のようなクッション性はない。しかし、隙間εに介在するクッション性に富む表層パッド４の軟質ポリウレタン発泡成形部４４が在ることによって、車両組付け下のシートパッド１において内芯体３に動きが生まれる。軟質ポリウレタン発泡成形部４４が内芯体３の動きに融通性を持たせている。乗員の着座時に合わせて快適なクッション性を付与する当たり面部分４１に加え、内芯体３が多少下動することで、シートパッド１の内部にクッション性に乏しい内芯体３が存在しても、良好なクッション性が得られる。図２,図３は筒状隙間εの幅を強調図示するが、内芯体３を大きくしてシートパッド１の軽量効果を高めるように設定しながら、乗員の着座時に内芯体３が、軟質ポリウレタン発泡成形部４４の弾性変形で、多少でも下動できるように筒状隙間εの幅が選定されると、より好ましくなる。 Here, the bead foam molded body constituting the outer core body 2 and the inner core body 3 does not have cushioning properties unlike the soft polyurethane molded body of the surface layer pad 4. However, the presence of the soft polyurethane foam molded portion 44 of the surface layer pad 4 rich in cushioning intervening in the gap ε causes the inner core body 3 to move in the seat pad 1 under vehicle assembly. The flexible polyurethane foam molded portion 44 provides flexibility in the movement of the inner core body 3. In addition to the contact surface portion 41 that provides comfortable cushioning according to the occupant's seating, the inner core body 3 slightly moves down, so that the inner core body 3 with poor cushioning is present inside the seat pad 1. Also, good cushioning properties can be obtained. 2 and 3 highlight the width of the cylindrical gap ε, while the inner core body 3 is set so as to increase the light weight effect of the seat pad 1 while enlarging the inner core body 3, It is more preferable that the width of the cylindrical gap ε is selected so that the flexible polyurethane foam-molded part 44 can be moved down somewhat by elastic deformation.

本表層パッド４は、図２でいえば、着座乗員の当たり面部分４１側となる上面側の部分を形成するだけでなく、意匠面４ａ側になる車両前方側パッド側面４３１や車両後方に向かう斜面４Ｄ、さらにバックレストの合わせ面４Ｅに表層パッド４の表層部を形成する。同図で、表層パッド４の下縁部分４２は外芯体２の下面側外周縁２４１まで覆っており、シートパッド１の見栄えを良くしている。
尚、表層パッド４は、図１のごとく車両後方側の中央部のパッド側面４３を切欠いて、そこに外芯体２が露出するが、パッド側面４３の全周に亘って厚みが小の表層パッド４の層を設けることも勿論できる。本シートパッド１が出来上がり、車両取付け姿態の図２の状態にすれば、外芯体２に組み込んだ前記Ｕ字形フック２Ｂは、一方が下向きに、他方が水平後方に突き出す格好となる(図２,図３)。図中、符号４Ａは表層パッド４の乗員が着座するメイン座部、符号４９は表層パッド４の吊溝、符号９は表皮を示す。 In FIG. 2, the surface layer pad 4 not only forms a portion on the upper surface side that is the contact surface portion 41 side of the seated occupant, but also faces the vehicle front side pad side surface 431 that becomes the design surface 4 a side and the vehicle rear side. The surface layer portion of the surface layer pad 4 is formed on the slope 4D and the mating surface 4E of the backrest. In the same figure, the lower edge portion 42 of the surface layer pad 4 covers up to the outer peripheral edge 241 on the lower surface side of the outer core body 2 to improve the appearance of the seat pad 1.
As shown in FIG. 1, the surface layer pad 4 has a pad side surface 43 at the center on the rear side of the vehicle cut out, and the outer core body 2 is exposed there. However, the surface layer has a small thickness over the entire circumference of the pad side surface 43. Of course, the layer of the pad 4 can also be provided. When the seat pad 1 is completed and the vehicle is mounted as shown in FIG. 2, the U-shaped hook 2B incorporated in the outer core body 2 is shaped so that one protrudes downward and the other protrudes horizontally rearward (FIG. 2). , FIG. 3). In the figure, reference numeral 4A denotes a main seat where an occupant of the surface layer pad 4 sits, reference numeral 49 denotes a hanging groove of the surface layer pad 4, and reference numeral 9 denotes a skin.

このように構成した車両用シートパッド１は、環状形成された外芯体２とこの環状内に配される内芯体３とを具備し、両者を別箇独立させて、ビーズ発泡成形体からなる内芯体３を外芯体２のビーズ発泡成形体よりも発泡倍率を高くしているので、シートパッド１の必要な部位の寸法精度を、外芯体２に担わせる一方、内芯体３に軽量化を担わせて、軽量にして寸法精度に優れた品質良好な車両用シートパッド１を簡単に得ることができる。外芯体２と内芯体３にビーズ発泡成形体を用いながら、双方の発泡倍率を変えることによって、車両へのシートパッドの組付け不良を起こさず、シートパッドの安定生産を図って、且つ大幅な軽量化を実現する。 The vehicle seat pad 1 configured as described above includes an outer core body 2 formed in an annular shape and an inner core body 3 disposed in the annular shape. Since the inner core body 3 has a higher foaming ratio than the bead foam molded body of the outer core body 2, the outer core body 2 is responsible for the dimensional accuracy of the necessary part of the seat pad 1, while the inner core body Therefore, it is possible to easily obtain the vehicle seat pad 1 that is light in weight, excellent in dimensional accuracy, and good in quality. While using bead foam moldings for the outer core body 2 and the inner core body 3, by changing the expansion ratio of both, the seat pad can be assembled stably to the vehicle without causing improper assembly of the seat pad, and Realize significant weight reduction.

ＥＰＰ等のビーズ発泡成形体は、発泡倍率を上げて密度を小さくし軽量化できるが、発泡倍率が高くなると寸法精度が悪くなる。寸法精度の観点から発泡倍率が25倍〜30倍が推奨されているが、例えばＥＰＰのビーズ発泡成形体の芯体は、軽量化を目指して30倍程度にすると、寸法精度が悪化し苦労する。シートパッド１の発泡成形型に芯体をセットして表層パッド４を一体発泡成形しようとしても、セットに困難を伴う。芯体がひねったり反ったりして、発泡成形型へのセットが難しい。
また、シートパッド１を車両に取付け固定する時、シートパッド１に一体化させた車両取付け具のＵ字形フック２Ｂが基準になるが、Ｕ字形フック２Ｂがシートパッド１のなかで精度良く配設されていないと、シートパッド１が車両に上手く取付けられない。取付けることができても、シートパッド１の一部が浮き上がったり変形を起こしたりする。
本発明は、こうした問題をシートパッド１で表層パッド４に比べて大きな体積を占める芯体を外芯体２と内芯体３の二つに分け、且つ双方の発泡倍率(密度)を変えて解決する。本発明者は、シートパッド１のなかで、寸法精度が要求されるＵ字形フック２Ｂや表皮端部９１の固定用溝２５がシートパッド１の裏面外周縁沿いにあることを見出し、軽量を担う内芯体３とは別に、Ｕ字形フック２Ｂ及び固定用溝２５の領域部分を低発泡倍率の環状外芯体２に分離構成させることによって、車両への取付け基準となるＵ字形フック２Ｂが寸法精度良好に組み込まれた高品質のシートパッド１に仕上げることを可能にした。そして、環状外芯体２の突抜け穴２０に収まる別体の内芯体３は、寸法精度にとらわれることがないので、発泡倍率を極力上げて低密度のビーズ発泡成形体の内芯体３とすることでシートパッド１の軽量化に存分に貢献できるようにした。
外芯体２の主部２Ａを、車両へのシートパッド１の組付けに寸法精度が要求される低発泡倍率のビーズ発泡成形体にする一方、内芯体３のビーズ発泡成形体の発泡倍率を外芯体２の発泡倍率よりも高くすると、必要な寸法精度を確保しながら、内芯体３の密度が小さくなって内芯体３を簡単に軽くでき、ひいてはシートパッド全体を軽量化できる。Ｕ字形フック２Ｂの寸法精度を良好にして、軽量化を実現したシートパッド１が出来上がる。
加えて、外芯体２に環状ワイヤ２Ｃを埋設し、Ｕ字形フック２Ｂが該環状ワイヤ２Ｃに接続する構成にすると、環状ワイヤ２Ｃによって外芯体２の精度を更に保つようにできるので、該Ｕ字形フック２Ｂを介して外芯体２、ひいてはシートパッド１が車両により確実且つ安定に取付け固定できる。 A bead foam molded article such as EPP can increase the expansion ratio to reduce the density and reduce the weight, but the dimensional accuracy becomes worse as the expansion ratio increases. From the viewpoint of dimensional accuracy, a foaming ratio of 25 to 30 times is recommended. For example, if the core of an EPP bead foam molded body is about 30 times aiming at weight reduction, the dimensional accuracy deteriorates and it is difficult. . Even if the core body is set in the foaming mold of the seat pad 1 and the surface layer pad 4 is integrally foam-molded, it is difficult to set. The core is twisted or warped, making it difficult to set in a foam mold.
Further, when the seat pad 1 is attached and fixed to the vehicle, the U-shaped hook 2B of the vehicle attachment unit integrated with the seat pad 1 is used as a reference, but the U-shaped hook 2B is accurately arranged in the seat pad 1. Otherwise, the seat pad 1 cannot be attached to the vehicle successfully. Even if it can be attached, a part of the seat pad 1 is lifted or deformed.
The present invention divides the core body that occupies a larger volume in the seat pad 1 than the surface layer pad 4 into the outer core body 2 and the inner core body 3 and changes the expansion ratio (density) of both. Solve. The inventor finds that the U-shaped hook 2B and the fixing groove 25 of the skin end portion 91 that require dimensional accuracy are located along the outer peripheral edge of the back surface of the seat pad 1 in the seat pad 1, and bears light weight. Separately from the inner core body 3, the U-shaped hook 2B and the fixing groove 25 are separated into the annular outer core body 2 having a low expansion ratio so that the U-shaped hook 2B serving as a reference for mounting on the vehicle is dimensioned. It was possible to finish the high-quality seat pad 1 incorporated with good accuracy. Since the separate inner core body 3 that can be accommodated in the through hole 20 of the annular outer core body 2 is not limited by dimensional accuracy, the inner core body 3 of the low-density bead foam molded body can be obtained by increasing the expansion ratio as much as possible. By doing so, it was possible to contribute to the weight reduction of the seat pad 1.
The main portion 2A of the outer core body 2 is a low foaming ratio bead foam molded body that requires dimensional accuracy for assembly of the seat pad 1 to the vehicle, while the foaming ratio of the inner core body 3 bead foam molded body. Is made higher than the expansion ratio of the outer core body 2, while the required dimensional accuracy is secured, the density of the inner core body 3 is reduced and the inner core body 3 can be easily lightened, and the entire seat pad can be reduced in weight. . The seat pad 1 that achieves light weight by improving the dimensional accuracy of the U-shaped hook 2B is completed.
In addition, if the annular wire 2C is embedded in the outer core body 2 and the U-shaped hook 2B is connected to the annular wire 2C, the accuracy of the outer core body 2 can be further maintained by the annular wire 2C. The outer core body 2 and consequently the seat pad 1 can be securely and stably attached and fixed by the vehicle via the U-shaped hook 2B.

また、表層パッド４は、外芯体２とその環状内に配した内芯体３とを埋設一体化している軟質ポリウレタン発泡成形体にして、乗員が当接する側の意匠面４ａ側に所定厚みの当たり面部分４１を有しているので、シートパッド１のクッション性が良好に保たれる。
さらに、外芯体２とその環状内に配設した内芯体３との間に隙間εが設けられ、該隙間εが表層パッド４に係る軟質ポリウレタン発泡成形部４４で埋められていると、該軟質ポリウレタン発泡成形部４４が緩衝材になるので、乗員着座時等で外芯体２と内芯体３との接触による擦れ音を発生させない。
さらにいえば、隙間εがクッション性に富む軟質ポリウレタン発泡成形部４４で埋められると、乗員の着座時にその重みに対応して、外芯体２から切り離された独立状態にある内芯体３が下動するので、表層パッド４に比しクッション性に乏しい内芯体３を内在させても違和感のない従来と同等のクッション性を有する品質的に優れたシートパッド１になる。
このように本車両用シートパッド１は、上述した種々の優れた効果を発揮し極めて有益である。 Further, the surface layer pad 4 is a flexible polyurethane foam molded body in which the outer core body 2 and the inner core body 3 disposed in the annular shape are embedded and integrated, and has a predetermined thickness on the design surface 4a side on which the occupant abuts. Therefore, the cushioning property of the seat pad 1 is kept good.
Further, when a gap ε is provided between the outer core body 2 and the inner core body 3 disposed in the ring, and the gap ε is filled with the soft polyurethane foam molded portion 44 according to the surface layer pad 4, Since the flexible polyurethane foam molded portion 44 is a cushioning material, no rusting noise is generated due to contact between the outer core body 2 and the inner core body 3 when a passenger is seated.
More specifically, when the gap ε is filled with the soft polyurethane foam molded portion 44 having a high cushioning property, the inner core body 3 in an independent state separated from the outer core body 2 corresponds to the weight when the occupant is seated. Since it moves downward, even if the inner core 3 having poor cushioning properties compared to the surface layer pad 4 is incorporated, the seat pad 1 having a cushioning property equivalent to that of the conventional one without any discomfort is obtained.
Thus, the vehicle seat pad 1 exhibits the various excellent effects described above and is extremely useful.

尚、本発明においては前記実施形態に示すものに限られず、目的,用途に応じて本発明の範囲で種々変更できる。シートパッド１,外芯体２,内芯体３,表層パッド４等の形状,大きさ,個数,材質等は用途に合わせて適宜選択できる。実施形態は座部用クッションパッドにしたが、背もたれ用バックパッドにも適用できる。また、上記実施形態では、車両取付け具にＵ字形フック２Ｂを例に挙げたが、これに限らず、例えば車両に係合するクリップなどを用いてもよい。更に、上記実施形態では、外芯体２にＵ字形フック２Ｂが接続する環状ワイヤ２Ｃが埋設されていたが、環状ワイヤ２Ｃを埋設しなくてもよい。その場合は、車両取付け具を単体で外芯体２に一体化させておけばよい。 The present invention is not limited to those shown in the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, and the like of the seat pad 1, the outer core body 2, the inner core body 3, the surface layer pad 4 and the like can be appropriately selected according to the application. Although the embodiment is a cushion pad for a seat, it can also be applied to a back pad for a backrest. Moreover, in the said embodiment, although the U-shaped hook 2B was mentioned as the example in the vehicle attachment tool, you may use not only this but the clip etc. which engage with a vehicle, for example. Furthermore, in the said embodiment, although the annular wire 2C which the U-shaped hook 2B connects to the outer core body 2 was embedded, it is not necessary to embed the annular wire 2C. In that case, what is necessary is just to integrate the vehicle attachment tool in the outer core body 2 alone.

１シートパッド
２外芯体
２Ａ主部
２ＢＵ字形フック
２Ｃ環状ワイヤ
２５表皮端部の固定用溝（固定用溝）
３内芯体
４表層パッド
４ａ意匠面
４１当たり面部分（着座乗員の当たり面部分）
４４軟質ポリウレタン発泡成形部
ε 隙間（環状隙間） DESCRIPTION OF SYMBOLS 1 Seat pad 2 Outer core body 2A Main part 2B U-shaped hook 2C Annular wire 25 The groove | channel for fixing | fixing a skin end part (fixing groove)
3 inner core body 4 surface layer pad 4a design surface 41 contact surface portion (contact surface portion of seated occupant)
44 Flexible polyurethane foam molding ε Clearance (annular clearance)

Claims

In the vehicle seat pad in which at least the contact surface portion on the side where the occupant abuts is formed of a soft polyurethane foam molded body,
An outer core body that is molded in an annular shape with the main part of the bead foam molded body as a main component;
An inner core body comprising a bead foam molded body having an expansion ratio higher than that of the bead foam molded body of the outer core body, and disposed in an annular shape of the outer core body;
A soft polyurethane foam molded body in which the outer core body and the inner core body disposed in the ring are embedded and integrated, and a surface layer pad having the contact surface portion on the design surface side. Vehicle seat pad.

The vehicle seat pad according to claim 1, wherein the outer core body is formed by inserting a vehicle attachment tool and the main portion is formed.

The vehicle seat pad according to claim 1 or 2, wherein a fixing groove at an end portion of the skin is formed on a back surface of the outer core body.

The vehicle seat pad according to claim 2 or 3, wherein an annular wire to which the vehicle attachment tool is connected is embedded in the outer core body.

5. The gap according to claim 1, wherein a gap is provided between the outer core body and the inner core body disposed in the annular shape, and the gap is filled with a soft polyurethane foam molded portion according to the surface layer pad. The vehicle seat pad according to claim 1.