Cushion body, seat, and method of manufacturing the same
OwnerMika Ito, Yasuchika Takeiinventors
Life of this patent
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Abstract
A cushion body, which can secure both a soft touch feeling and favorable shape reproduction of a groove portion, a seat having the same, and a manufacturing method thereof are provided. A cushion body 11 is formed by stacking a plurality of sheet-like fibrous structures 4a to 4e, a groove portion 12 is formed in a surface layer, and the sheet-like fibrous structures 4a to 4e have a web 2 stacked so that the web extends in a thickness direction of the fibrous structures. The surface layer sheet-like fibrous structure 4e has a thickness substantially equal to or smaller than a depth of the groove portion 12.
Claims19
1-12. (canceled)
A molded cushion body comprising a stack of a plurality of fibrous structures, wherein each of the fibrous structures comprises a mix of main fibers and binder fibers and has a corresponding predetermined shape, wherein the molded cushion body includes a groove portion formed as a recess in a thickness direction and in a surface layer comprising one of the fibrous structures, wherein each of the fibrous structures comprises plural folds of a web, wherein the web comprises a blend of the main fibers and the binder fibers along the thickness direction, and wherein the surface layer has a thickness substantially equal to or smaller than a depth of the groove portion.
A method of manufacturing a cushion body comprising:
- forming a plurality of fibrous structures by successively folding a web composed of main fibers and binder fibers;
- stacking the fibrous structures to form a stack of fibrous structures;
- disposing the stack of fibrous structures in a compressed state in a mold having a groove formation portion for forming a groove portion as a recess in a thickness direction of the cushion body, wherein the groove formation portion is formed on a mold face of the mold so as to form the groove portion in an outer one of the fibrous structures, and wherein the outer one of the fibrous structures has a thickness substantially equal to or smaller than a depth of the groove portion resulting from contact with the groove formation portion;
- and,
- thermally molding the stack of fibrous structures in the mold to form the cushion body.
A method of manufacturing a seat comprising:
- forming a plurality of fibrous structures by successively folding a web composed of main fibers and binder fibers;
- stacking the plurality of fibrous structures to form a stack of fibrous structures;
- disposing the stack of fibrous structures and a cover in a compressed state in a mold having a groove formation portion for forming a groove portion in an outer one of the fibrous structures, wherein the groove portion is formed as a recess in a thickness direction of the cushion body, wherein the groove formation portion is on a mold face of the mold, and wherein the outer one of the fibrous structures has a thickness substantially equal to or smaller than a depth of the groove portion resulting from contact between the outer one of the fibrous structures and the groove formation portion through the cover;
- thermally molding the fibrous structures in the mold so as to form the cushion body on which the cover is affixed on a surface;
- and,
- attaching the molded cushion body to a seat frame.
A method of manufacturing a cushion body comprising:
- stacking a plurality of fibrous structures to form a stack of fibrous structures, wherein each of the fibrous structures comprises a mix of main fibers and binder fibers, wherein each of the fibrous structures comprises plural folds of a web, wherein the web comprises a blend of the main fibers and the binder fibers along a load direction of the cushion body;
- compressing the stack of fibrous structures in a mold so as to form a groove portion as a recess in the load direction and in an outer one of the fibrous structures, wherein the outer one of the fibrous structures has a thickness substantially equal to or smaller than a depth of the groove portion;
- and,
- blowing steam to the fibrous structures through steam holes formed through the mold so as to mold the stack of fibrous structures into the cushion body.
Dependencies are inferred from the claim text.