JPH11137364A - Vehicle seat and manufacturing method thereof - Google Patents

Abstract

(57) Abstract: Provided is a vehicle seat having good durability and high durability, and a method of manufacturing the same. A cushion block (25) having a plurality of hollow portions (24a to 24g) formed inside a resin frame (22).
a to 25d and the skins 23a to 23d are completed as a cushion part having an integral structure and a uniform thickness. A plurality of hollow portions 24a formed inside the frame 22,
24 g and 24 e are filled with a foamable resin, and the entire vehicle seat 10 is integrally formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle seat and a method of manufacturing the same, and more particularly, to a vehicle seat having good sitting comfort and high durability, and a method of manufacturing the same.

[0002]

2. Description of the Related Art A vehicle seat includes a seat cushion, a seat back, and a headrest. In the prior art, these have three main components, respectively, a frame, a cushion body that receives and supports the occupant's body, and a skin that is a part that the occupant's body directly touches. In general, among these members, a frame formed by assembling a steel pipe or a steel plate pressed part is used as the frame, a foamed synthetic resin material is used as the cushion body, and a genuine leather or vinyl leather is used as the skin. And other materials cut and sewn are used.

In the above prior art, a seat cushion,
After manufacturing the seat back and the headrest from the frame to the skin in separate processes, the vehicle seat is obtained by assembling the seat cushion, the seatback and the headrest as a finished product. Also, seat cushion,
In some cases, only the cushion body of the seat back and the headrest are integrally formed and then molded with a frame manufactured in a separate process and further covered with a skin to obtain a completed vehicle seat.

[0004] As described above, in the production of a vehicle seat, a large number of steps are required.
There is a demand for a technology for manufacturing with high production efficiency.
Naturally, in this case as well, it is necessary to maintain good performance of the vehicle seat, and as described above, it is necessary to obtain a good sitting comfort with the basic function of receiving the occupant's body and having a sense of stability. In addition, high durability is also an essential requirement.

As a technique for manufacturing a vehicle seat while maintaining this high production efficiency, a seat in which a cushion material forms a skin by itself at the time of forming the seat, and the skin and the cushion body are integrally formed, is being studied.

For example, Japanese Patent Application Laid-Open No. 46-6634 discloses a technique in which a cushion portion made of an expandable polyurethane material is directly formed on a sheet pan made of a steel plate in one manufacturing process. Since the foamable polyurethane material forms the skin itself, the cushion body and the skin are integrally formed.

[0007]

However, in such a method of forming the skin and the cushion body into an integral structure, it is necessary to reliably discharge gas generated during foam molding to obtain a uniform foamed state. It is difficult, and it is difficult to form a structure in which the skin having a uniform thickness on the entire surface and the cushion body are integrated. The seat having the skin formed in this way has a stiff feel, and when the occupant sits down, there is a problem that sitting comfort is poor and durability is poor.
In addition, it has been pointed out that such a seat having an integral structure of the skin and the cushion body does not significantly improve the production efficiency.

The present invention has been made in consideration of such problems, and has no stiff feel when an occupant is seated, can well follow the occupant's body shape, has less sinking, It is an object of the present invention to provide a vehicle seat that can obtain good sitting comfort, has high durability, and improves production efficiency, and a method for manufacturing the same.

[0009]

According to the present invention, there is provided a vehicle seat comprising a frame, a cushion main body, and a skin covering the cushion main body. Are integrally formed, and the frame has a wall portion forming a hollow portion inside, and the wall portion introduces a foaming resin introduced from the hollow portion and simultaneously transmits gas generated during molding to the outside. It has a plurality of holes for leading out, and the foamable resin is filled in the hollow portion.

According to the above vehicle seat, since the hollow portion is filled with the foaming resin, the rigidity is increased, and the gas generated at the time of molding is discharged from the hollow portion to the outside. It does not remain inside the body or in the skin. Therefore, a uniform foaming state is obtained,
In addition, the seating comfort is good and the durability is improved. As described above, since the vehicle seat can be obtained without much trouble, there is an advantage that productivity is improved.

Further, the present invention is characterized in that the cushion main body is divided into a plurality of cushion blocks.

In this case, since the cushion body is composed of a plurality of cushion blocks integrally formed with the skin, the foamable resin is introduced into each cushion block with the same pressure, and as a result, the foam is uniformly foamed. Thus, an integrated structure can be obtained.

Further, the present invention is characterized in that the skin and the cushion body are made of urea resin.

When the foamable resin is composed of a urea resin, the effect of further improving the durability can be obtained.

Further, the method for manufacturing a vehicle seat according to the present invention is directed to a method for manufacturing a vehicle seat comprising a frame, a cushion main body, and a skin covering the cushion main body. After placing a frame having a plurality of holes and a hollow portion communicating with the foaming resin injection port for molding in the cavity formed by the above, and clamping the first and second molds Filling the cavity with the foamable resin from the injection port through the plurality of holes in the hollow portion, and solidifying the foamable resin in the cavity, and then opening the mold to form the mold into the hollow portion of the frame. It is characterized in that a sheet is obtained in which a part of the foamable resin is filled and the skin and the cushion body are integrally formed.

According to this method, since the foamable resin is preferably introduced into the hollow portion by branching from the portion corresponding to the lower portion of the sheet of the frame, the shielding material does not exist. The molten metal made of the foamable resin can be quickly and smoothly circulated, and an integral structure as a cushion having a skin having a uniform thickness can be obtained.

In addition, since the gas generated in the portion corresponding to the cushion body is led out through the hollow portion, the gas does not remain in the cavity, and a high quality sheet can be obtained.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of a vehicle seat according to the present invention in connection with a manufacturing method thereof will be described below in detail with reference to FIGS.

FIG. 1 shows a vehicle seat 10 according to the present invention. When the vehicle seat 10 is completed, the cushion portion 14 is sandwiched between the side portions 12a and 12b that bulge forward in the traveling direction at the time of completion.
a, the second cushion portion 16b and the third cushion portion 1
6c, a headrest portion 16d is formed above the third cushion portion 16c.

FIG. 2 is a sectional view taken along the line II-II of FIG.
FIG. 3 is a sectional view taken along line III-III of FIG. In the vehicle seat 10 shown in FIGS. 2 and 3, the cushion portion 14 is composed of a skin 18 and a cushion main body 20 formed as an integral structure by solidifying a foamable resin.
The cushion body 20 is firmly held by the frame 22.

As shown in FIG.
Is a horizontal hollow portion 24a having an inlet 21 for molten resin.
And a relatively long hollow portion 24b for the backrest extending upward from the horizontal hollow portion 24a, and a hollow portion 24c for the headrest formed integrally with the upper end of the hollow portion 24b for the backrest. Have. The hollow portion 24b for the backrest
Are formed on both sides thereof along the longitudinal direction thereof.
24e, hollow portions 24f, 24
g is formed. A plurality of holes 26 for leading the foamable resin from the inside toward the backrest hollow portion 24b are provided on the opposing side surfaces of the reinforcing hollow portions 24d and 24e at predetermined intervals. I have.

Therefore, referring to FIG. 3, the cushion portion 14 has the first cushion portion 16a, the second cushion portion 16b, and the third cushion portion 16c as described above, and these first to third cushion portions 16a are provided. ~ 16c
It includes first to third cushion blocks 25a to 25c.
These first to third cushion blocks 25a to 25c
The surface is preferably formed integrally with skins 23a to 23c made of a urea resin. on the other hand,
The headrest portion 16d includes a headrest cushion block 25d, and the cushion block 25d is integrally formed with a skin 23d.

In this case, the cushion portion 14, ie,
First to third cushion blocks 25a to 25c, cushion block for headrest 25d, skins 23a to 23
As the material of d, a foamable urethane resin or urea resin can be suitably used. Further, as the frame 22, a resin obtained by hollow injection molding of a resin such as a polypropylene resin is preferably used.

Next, the vehicle seat 1 according to the present embodiment will be described.
0 will be described with reference to FIGS.

Here, FIG. 5 shows a conceptual diagram of the cavity portion 30 defined in advance in relation to the structure of the mold for manufacturing the sheet 10 in advance. The cavity 30
Has substantially the same shape as the vehicle seat 10 of FIG. Therefore, the cavity 30 is provided in the vehicle seat 1.
Cavities 32a corresponding to the side portions 12a, 12b of
32b, a cavity 34a corresponding to the first cushion 16a, a cavity 34b corresponding to the second cushion 16b, a cavity 34c corresponding to the third cushion 16c, and a cavity 34d corresponding to the headrest 16d.

The mold 40 shown in FIG. 6 includes an upper mold 42 and a lower mold 44, and the cavity 30 is defined between the upper mold 42 and the lower mold 44. reference). In this case, a plurality of suction holes 43 are provided in the upper mold 42, and these suction holes 43 are connected to a negative pressure supply source (not shown). On the other hand, the reinforcing hollow portions 24d and 24e extending in the longitudinal direction of the frame 22 are connected to the sprue 48 of the foamable resin injection device 46 shown in FIG.
To form a runner at the time of foaming resin injection. Further, these hollow portions 24d and 24e and the cavity 34b
The hole 2 serving as a gate provided in the frame 22
6 are connected. In the figure, reference numeral 50 is used.
Indicates a parting line formed on the mating surface between the upper mold 42 and the lower mold 44.

Next, a method of manufacturing the vehicle seat 10 using the mold 40 will be described.

First, while the frame 22 made of a molded product is fixed to the upper mold 42 by suction through the plurality of suction holes 43, the lower mold 44 is preliminarily heated to about 50 to 60 ° C.
Preferably, a urea resin having a thickness of 0.5 to 1.
Spray uniformly to about 0 mm. A skin portion is formed by the urea resin. Next, the mold 40 is clamped. Next, the process proceeds to the injection of the foamable resin and the molding operation.

In FIGS. 6 and 7, the foaming resin, preferably urea resin, injected from the sprue 48 of the injection port using the foaming resin injection device 46 is supplied to the horizontal hollow portion 2.
4a through the molten resin inlet 21 and the reinforcing hollow portion 24
d, 24e are supplied to the upper surface of the hollow portion 24b for the backrest, and finally the hollow portion 2 for the headrest.
4c. Therefore, the solidified foamable resin is filled into the inside of the horizontal hollow portion 24a and the reinforcing hollow portions 24d and 24e in a solid state. Therefore, the frame 22 and the cushion portion 14 are reliably integrated. On the other hand, the hollow portion 24 b for the backrest and the hollow portion 2 for the side portion of the frame 22.
There is no filling of the foamable resin inside the 4f and 24g. These are hollow, and the rigidity is increased and the weight of the seat is reduced.

The injection state of the foamable resin will be described with reference to the conceptual diagram of the cavity portion 30 in FIG.
The foamable resin is divided into four through the molten resin injection port 21 and the hole 26 with respect to 34c and the cavity 34d,
5, it is supplied in the direction indicated by the arrow. During this time, gas generated by the injection of the foaming resin remains in the cushion portions 16a to 16d shown in FIG. 7, and a part of excess gas flows into the hollow portion 24b through the hole 27. When the upper mold 42 is separated from the lower mold 44 at the timing when the foamable resin of the cushion portions 16a to 16d is substantially solidified, the gas is used as a parting line between the upper mold 42 and the lower mold 44. It will be discharged instantly from 50 to the outside.

During this time, that is, the upper mold 42 and the lower mold 4
4 are joined to each other while the cavity 34a
To 34d and the hollow portion 24d for reinforcement of the frame 22;
4e and the horizontal hollow portion 24a are filled with a foaming resin,
It is foam molded.

After a predetermined time, for example, about 40 to 120 seconds, the solidified vehicle seat 10 is taken out as a finished product by separating the upper mold 42 from the lower mold 44.

[0033]

As described above, in the vehicle seat according to the present invention, the skin, the cushion body and the frame are integrally formed, and a plurality of blocked cushions having the skin with a uniform thickness can be obtained. Can be That is, since the thickness of the skin is uniform, there is no stiff feeling, and since the cushion portion is constituted by a plurality of divided blocks, the shape of the occupant can be satisfactorily imitated, and the seating comfort can be improved. A good sheet can be obtained.
Furthermore, since a part of the hollow portion in the frame is filled with the foamable resin, the cushion portion and the frame are reliably integrated, and a highly durable vehicle seat can be obtained.

According to the method of manufacturing a vehicle seat according to the present invention, a part of the hollow portion of the frame is used as a runner for injecting the foamable resin, and each cavity portion corresponding to the plurality of divided cushion blocks is provided. The foaming resin can be injected and the generated gas can be discharged. For this reason,
It is possible to suitably manufacture a vehicle seat having a cushion portion in which a skin, a cushion main body, and a frame have an integral structure and a skin having a uniform thickness. Also, when forming the cushion portion into a plurality of divided blocks,
There is an advantage that a special runner does not need to be used and the structure is simplified.

[Brief description of the drawings]

FIG. 1 is a perspective view of a vehicle seat according to an embodiment.

2 is a cross-sectional view of the vehicle seat of FIG. 1 taken along the line II-II.

FIG. 3 is a sectional view taken along line III-III of the vehicle seat of FIG. 1;

FIG. 4 is a schematic perspective explanatory view of a frame incorporated in the vehicle seat of FIGS. 1 to 3;

FIG. 5 is a conceptual diagram illustrating a flow path of a foamable resin in a cavity in a mold when the vehicle seat according to the present embodiment is formed.

6 is a cross-sectional view of a mold corresponding to the cavity of FIG.

FIG. 7 is a longitudinal sectional view of a mold corresponding to the cavity of FIG.

[Description of Signs] 10 ... Vehicle Seats 12a, 12b
… Side part 14, 16a-16c… cushion part 16d… headrest part 18, 23a-23d… skin 20… cushion body 22… frame 24a-24g
... hollow portions 25a to 25d ... cushion blocks 30 ... cavity portions 32a to 32d, 34a to 34d ... cavities 40 ... molds 42 ... upper molds 44 ... lower molds 46 ... foaming resin injection device

Claims (6)

[Claims] 1. A vehicle seat comprising a frame, a cushion main body, and a skin covering the cushion main body, wherein the skin and the cushion main body are integrally formed by a foamable resin, and the frame is provided inside. It has a wall portion forming a hollow portion, the wall portion has a plurality of holes for introducing a foamable resin introduced from the hollow portion and leading out gas generated at the time of molding to the outside, and A vehicle seat, wherein the foamable resin is filled in the hollow portion. 2. A vehicle seat according to claim 1, wherein said cushion main body is divided into a plurality of cushion blocks. 3. The vehicle seat according to claim 1, wherein the skin and the cushion body are made of urea resin. 4. A method of manufacturing a vehicle seat comprising a frame, a cushion main body, and a skin covering the cushion main body, wherein a plurality of holes are formed in a cavity formed by the first and second molds. After placing a frame having a hollow portion communicating with the foaming resin injection port for molding and mounting the first and second molds, the foaming resin is discharged from the injection port into the hollow portion. After filling the cavity through the plurality of holes, the foamable resin in the cavity is solidified, and then the mold is opened to partially fill the hollow portion of the frame with the foamable resin, and A method for manufacturing a vehicle seat, comprising obtaining a seat integrally formed with a cushion body. 5. A method for manufacturing a vehicle seat according to claim 4, wherein a gas generated during molding is led out of a mold through a hollow portion of said frame. . 6. The method for manufacturing a vehicle seat according to claim 4, wherein the foamable resin is made of a urea resin.