Flexible polyurethane foam molded article, and seat pad

Patent metadata

Field	Value
Publication number	US-10549666-B2
Application number	US-201615770057-A
Country	US
Kind code	B2
Filing date	Nov 10, 2016
Priority date	Nov 11, 2015
Publication date	Feb 4, 2020
Grant date	Feb 4, 2020

Abstract

A flexible polyurethane foam molded article includes a plurality of layer parts (L1 to L10) that are layered in a vertical direction (Y) perpendicular to a stage surface (1A). When the entire flexible polyurethane foam molded article is compressed by 15% in the vertical direction (Y), the front surface layer (L1) positioned closest to the stage surface (1A) in the vertical direction (Y) among the plurality of layer parts (L1 to L10) has the lowest residual thickness ratio in the vertical direction (Y) among the plurality of layer parts (L1 to L10). When the entire flexible polyurethane foam molded article is compressed by 50% in the vertical direction (Y), the back surface layer (L10) positioned closest to a non-stage surface (1B) of the flexible polyurethane foam molded article in the vertical direction (Y) among the plurality of layer parts (L1 to L10) has the highest residual thickness ratio in the vertical direction (Y) among the plurality of layer parts (L1 to L10).

First claim

The invention claimed is:

1. A flexible polyurethane foam molded article that has a stage surface, and an opposed non-stage surface,
the flexible polvurethane foam molded article obtained by foam molding a foaming stock solution comprised of a polyol, a polvisocyanate, a crosslinking agent, a foaming agent and a catalyst,
the flexible polyurethane foam molded article having a thickness of from 30 to 150 mm and comprising:
a plurality of foamed layers that are layered in a vertical direction perpendicular to the stage surface, the plurality of foamed layers being substantially equally divided in a horizontal direction parallel to the stage surface in a no-load state,
wherein, when the entire flexible polyurethane foam molded article is compressed by 15% in the vertical direction, a front surface layer positioned closest to the stage surface in the vertical direction among the plurality of foamed layers has the lowest residual thickness ratio in the vertical direction among the plurality of foamed layers,
wherein, when the entire flexible polyurethane foam molded article is compressed by 50% in the vertical direction, a back surface layer positioned closest to the non-stage surface in the vertical direction among the plurality of foamed layers has the highest residual thickness ratio in the vertical direction among the plurality of foamed layers, and
wherein the residual thickness ratio of the foamed layer refers to a ratio of a thickness of the foamed layer in a load-applied state with respect to a thickness of the foamed layer in the no-load state.

2. The flexible polyurethane foam molded article according to claim 1 ,
wherein, when the entire flexible polyurethane foam molded article is compressed by 40-50% in the vertical direction, the residual thickness ratio of the front surface layer decreases while a rate of change decreases.

3. The flexible polyurethane foam molded article according to claim 2 ,
wherein, when the entire flexible polyurethane foam molded article is compressed by 40-50% in the vertical direction, a residual thickness ratio in at least one layer positioned on the side of the non-stage surface relative to the center of the flexible polyurethane foam molded article in the vertical direction among the plurality of foamed layers decreases while a rate of change increases.

4. A seat pad which is used as a seating part attached to a vehicle, wherein the seat pad is the flexible polyurethane foam molded article according to claim 3 .

5. A seat pad which is used as a seating part attached to a vehicle, wherein the seat pad is the flexible polyurethane foam molded article according to claim 2 .

6. The flexible polyurethane foam molded article according to claim 1 ,
wherein, when the entire flexible polyurethane foam molded article is compressed by 40-50% in the vertical direction, a residual thickness ratio in at least one layer positioned on a side of the non-stage surface relative to the center of the flexible polyurethane foam molded article in the vertical direction among the plurality of foamed layers decreases while a rate of change increases.

7. A seat pad which is used as a seating part attached to a vehicle, wherein the seat pad is the flexible polyurethane foam molded article according to claim 6 .

8. A seat pad which is used as a seating part attached to a vehicle, wherein the seat pad is the flexible polyurethane foam molded article according to claim 1 .

Assignees

• Bridgestone Corp

Inventors

• Takahashi Yoshiyuki
• Yonezawa Taisuke

Classifications

• B32B5/32

  at least two} layers being foamed {and next to each other · CPC title

• A47C27/148

  of different resilience · CPC title

• B32B2605/003

  Interior finishings · CPC title

• B60N2/7035

  Cushions · CPC title

• B60N2/7017 Primary

  characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for · CPC title