Molded body, method of manufacturing the same, seat material for vehicles, and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9636853-B2
Application number	US-201414499593-A
Country	US
Kind code	B2
Filing date	Sep 29, 2014
Priority date	Sep 30, 2013
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

There is provided a molded body including a main portion and a bank portion each of which is formed by foaming and molding a foam material. The main portion is made of urethane material which is softer than the material for the bank portion. At a boundary portion between the main and bank portions, the main portion is formed in a continuous interlocking profile and the bank portion is also formed in another continuous interlocking profile. The interlocking profile and the another interlocking profile are mated to each other so as to prevent separation between the main portion and the bank portion in a direction of an arrow (vehicle width direction). The boundary portion is provided by partitioning the cavity in a single mold with a weir, introducing different foam materials into both sides of the weir and foaming the introduced materials.

First claim

We claim:

1. A molded body comprising:
a first molded object molded with a first foam material; and
a second molded object molded with a second foam material different from the first foam material,
wherein the first molded object and the second molded object each include an interlocking profile and the first molded object and the second molded object are interlocked to each other by means of respective interlocking profiles at a boundary portion between the first and second molded objects to prevent mutual separation of the first and second molded objects, and
wherein the first molded object includes an upright portion oriented upright and divided into a first member on an upper side thereof and a second member on a lower side thereof, the second member being positioned under the first member, the second member being molded with a foam material different from the first foam material, and the first and second members each include an interlocking profile and the first and second members are interlocked to each other by means of the respective interlocking profiles at a second boundary portion between the first and second members to prevent mutual separation of the members,
wherein the second boundary portion between the first and second members entirely linearly extends such that an extending direction of the second boundary portion obliquely intersects a thickness direction of the first member and the second member to form an acute angle with respect to the thickness direction of the first member and the second member.

2. A seat material for vehicles, comprising:
a main portion molded with a first foam material; and
a bank portion provided on each of both sides of the main portion and molded with a second foam material different from the first foam material,
wherein the main portion and the bank portion each include an interlocking profile and the main portion and the bank portion are interlocked to each other by means of respective interlocking profiles at a boundary portion between the main and bank portions to prevent mutual separation of the main and bank portions, and
wherein the main portion includes an upright seat back portion oriented upright and divided into a first member on an upper side of a vehicle and a second member on a lower side of the vehicle, the second member being positioned under the first member, the second member being molded with a foam material different from the first foam material, and the first and second members each include an interlocking profile and the first and second members are interlocked to each other by means of the respective interlocking profiles at a second boundary portion between the first and second members to prevent mutual separation of the members,
wherein the second boundary portion between the first and second members entirely linearly extends such that an extending direction of the second boundary portion obliquely intersects a thickness direction of the first member and the second member to form an acute angle with respect to the thickness direction of the first member and the second member.

3. The seat material for vehicles according to claim 2 ,
wherein the second member is molded with the foam material having a hardness after foaming higher than a hardness of the first member.

4. The seat material for vehicles according to claim 2 ,
wherein each of the interlocking profiles includes a bulbous projection.

5. The seat material for vehicles according to claim 2 ,
wherein each of the interlocking profiles includes a dovetail projection.

Assignees

• Honda Motor Co Ltd

Inventors

• Ishii Naoto
• Oku Hisato
• Koizumi Mai
• Nakajima Akira

Classifications

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B29L2031/771

  Seats · CPC title

• B29C44/0476

  by pouring more than one composition into an open mould · CPC title

• B29C44/353

  Means for guiding the foaming in, e.g. a particular direction · CPC title

• B29K2105/04

  cellular or porous · CPC title