JP2017165202A - Method of molding leg structure of composite vehicle seat and composite vehicle seat manufactured by the method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To save a weight of a vehicle seat as much as possible as well as to reduce cost of manufacturing and equipment by using FRP as a material of completely all main members for front and rear legs.SOLUTION: A rear leg 3 is constituted of: a downward inclined leg part 3A made of a composite material directed to a rear fixing part 1R inclined rear-downward from a front lateral member 6; and an upward inclined leg part 3B extending to rearward, to a rear lateral member 7 from a substantially intermediate part of the downward inclined leg part 3A. The front and rear legs have an I-shaped structure in which a web part 16 for receiving shear load, arranged on a YZ surface, and laminate configuration press-formed resin bodies 18 reinforced by continuous carbon fibers are arranged for the whole width or a part of an opposite web part side on flange parts 17 for receiving tension/compression axial forces and reinforcing rigidity. A leg structure formation method includes a step for injecting a compound resin to form an injection molding compound resin body 19 for a remaining area of the flange part 17 and the web part 16.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method of forming a leg structure of a vehicle seat made of a composite material, and more particularly to a method of manufacturing a leg structure of a vehicle seat including a front leg extending vertically and a rear leg reaching a rear fixing portion in an inclined state. is there. It is also intended to provide a composite vehicle seat manufactured by the method.

  The vehicle seat may be slightly displaced back and forth to change the position of the seating surface, but it can be secured to the floor at least during movement. In other words, the seat is in a stationary state in principle during movement, and the seat does not move forward with the passenger even if a slightly large deceleration acts on the passenger wearing the seat belt.

  In order to stabilize the seat, a metal material is applied to the leg structure, which provides sufficient strength and high rigidity. In the case of an aircraft seat, light metal is used, and it is often a cut-out product obtained by NC machining a forged aluminum product. In this case, the front leg, the rear leg, and the members attached to each are in principle a single product, and the leg structure is a combination thereof. By the way, from the viewpoint of increasing payload, cruising range, shortening takeoff and landing distance, the aircraft and equipment are required to be lighter.

  Japanese Patent Application Publication No. 2009-532255, which is Patent Document 1, proposes that the seat bottom frame and the seat back frame are made of laminated composite carbon fiber resin to reduce the weight of the seat. Japanese Patent Application Laid-Open No. 2009-537383, which is Patent Document 2, discloses that part of a component is made of fiber reinforced plastic so that the seat leg portion also has a lightweight structure. To describe the latter in more detail, a honeycomb core plate that enhances the overall structural strength is used together with a reinforcing bar material that is a metal rigid body, and FRP is used as a backing plate and a reinforcing plate on the front and back of the core plate.

  By the way, if it is going to make most parts of a leg structure into FRP, it cannot endure only with a front leg and a rear leg, but it is required to make it at least a truss structure. In that case, either the front leg, the rear leg, and the brace extending from the upper end of the front leg to the lower end of the rear leg are inserted, or the brace is extended from the lower end of the front leg to the upper end of the rear leg. These are forms in which only one brace is interposed, but when viewed from the left side of the seat, the former is N-shaped and the latter is inverted N-shaped (hereinafter referred to as N-shaped legs and inverted N-shaped legs). .

  The N-shaped leg is described in FIG. 1 of Japanese Patent Laid-Open No. 10-075848, which is Patent Document 3, and the inverted N-shaped leg is described in Japanese Patent Laid-Open No. 6-016194, which is Patent Document 4, but these are metal legs. It is not made of FRP. It goes without saying that it is important to use the properties of FRP if it is to be made of FRP legs. That is, consideration must be given to the strength of tensile force / compressive force and shear force, and the magnitude of bending strength. In addition, it is necessary to consider avoiding an increase in the size of the mold required for molding (reducing manufacturing costs).

  Regardless of whether the N-type leg or the inverted N-type leg is adopted, it is not preferable to keep the rear leg vertical in the rear portion of the seat in order to secure a space for accommodating the rider's legs and legs behind the seat. . Therefore, the rear leg is formed in a “<” shape as in Patent Document 3 described above. FIG. 17 (a) shows an example of a rear leg 42 in which a downward inclined part 41a in the latter half of the brace 41 and an upward inclined part 41b forming the upper part of the rear leg are combined, and an N-shaped leg is shown. Yes. FIG. 5B shows an example of a rear leg 44 that is a combination of an upward inclined portion 43a in the latter half of the brace 43 and a downward inclined portion 43b that forms the lower portion of the rear leg, and shows an inverted N-shaped leg.

  By the way, since the seat is fixed, a large deceleration G acts on the occupant when landing on the trunk, and a large force acts on the leg structure together with the inertial force of the seat itself. The leg structure is designed to withstand G as stipulated by laws and regulations, but needless to say, the leg structure is the front leg. The front leg may be deformed by a damper or the like to take measures to reduce the impact.

  According to the FEM analysis results with a large negative front G acting on each form, the N-shaped leg has a shearing force (black arrow) and moment (shaded arc arrow) acting compared to the inverted N-shaped leg. It is generally small, but on the other hand, the axial force (hatching arrow) is large. Therefore, in the case of an FRP molded product, an N-shaped leg is preferable in view of its advantages and disadvantages. The front leg 2 reaching the front fixing part 1F is generally vertical, but the rear leg is greatly inclined and the rear half part of the brace toward the rear fixing part 1R, and the upward inclination from the middle part of the brace toward the support girder of the rear edge of the seating surface. The structure is made up of parts.

Special table 2009-532255 Special table 2009-5337383 Japanese Patent Application Laid-Open No. 10-075848 JP-A-6-016194

  By the way, in order to obtain a high-strength FRP molded product, a prepreg laminating step and a heating / pressurizing / curing step by an autoclave are required, and much production time is required as compared with cutting out from a metal product. At the same time, a mold is indispensable. When a truss structure leg consisting of front legs, rear legs, and braces is integrally formed, even if the production time can be shortened, the mold must be enlarged, and as a result, an increase in production is inevitable.

  As can be seen from the above description, the leg structure in the seat of an aircraft has not yet been made of all FRP or mostly FRP. The weight reduction of each seat has a remarkable weight reduction effect in a large passenger aircraft equipped with, for example, 500 seats. Furthermore, the installation of seats made of or near total composite material will provide extremely important performance improvements for aircraft such as increased cruising range, reduced take-off and landing distance, and increased payload. The same applies to vehicles such as automobiles and ships.

  The present invention has been made in view of the above-mentioned problems, and its purpose is to reduce the weight of the seat as much as possible by completely FRP the main members of the front and rear legs, as well as tension, compression, shear, and bending moment. Considering the burden of the material, it is a FRP molded product with appropriate strength given to each part, but it is a structure that can exhibit rigidity, and waste of material usage while maintaining appropriate strength and proof strength FRP products that eliminate as much as possible, reduce the time required for molding FRP products that tend to take a lot of time, reduce the size of the molded products, and reduce the number of production To provide a composite vehicle seat structure molding method and a composite vehicle seat produced by the method, which can avoid the diversification and enlargement of molds and can reduce the cost of manufacturing and equipment. It is.

  The present invention is applied to a method for manufacturing a leg structure of a vehicle seat that includes a front leg that reaches a front fixing portion of a floor in a substantially vertical state, and a rear leg that faces a rear fixing portion in a downwardly inclined state. The feature is that mainly referring to FIG. 1, the leg structure 5 is lower than the front cross member 6 that supports the seat 4M (see FIG. 2B) and the adjacent seat 4N immediately below the front edge of the seating surface. The composite front leg 2 extending to the front and the front cross member 6 and the composite downward sloping leg portion 3A inclined downward and heading toward the rear fixing portion 1R, and the rearward from the substantially intermediate portion of the downward slant leg portion 3A. The rear leg 3 made of a composite material is formed by an inclined top leg 3B that is inclined and extends toward the rear lateral member 7 that supports the own seat 4M and the adjacent seat 4N immediately below the rear edge of the seating surface. Each of the front leg 2 and the rear leg 3 has a seat 4 (see FIG. 2 (a)) where the left and right are the X direction, the front and rear are the Y direction, and the top and bottom are the Z direction (see FIG. 2 (b)). ), An I-shaped structure (see FIG. 4) in which the web portion 16 bearing the shear load is arranged in the YZ plane (vertical plane extending in the front-rear direction of the seat), and bears the axial force of tension / compression and is rigid A continuous carbon fiber reinforced laminate-formed press-molded resin body 18 is disposed on the entire width or part of the flange part 17 on the side opposite to the web part and part of the web part (see FIG. 4), The remaining area in 17 and the remaining area in the web portion 16 are used as a compound resin body 19 for injection molding. Then, the injection compound resin is formed by molding the compound resin melt into the remaining cavity after the pre-molded continuous carbon fiber reinforced laminate press forming resin body 18 is placed in the mold as shown in FIG. In this case, the injection compound resin body and the laminate-formed press-molded resin body are integrated by resin fusion.

  The descending oblique leg portion 3A extends directly to the rear fixing part 1R, and the ascending oblique leg part 3B is integrally formed with the descending oblique leg part 3A at a substantially intermediate part of the descending oblique leg part 3A.

  The composite material front leg 2 and the composite material rear leg 3 are assembled as an integral structural leg via the front cross member 6 or the rear cross member 7.

  As shown in FIG. 11, the downward slant leg portion 3A has a front slant leg element 3F coupled to the front cross member 6 and a back slant leg element 3R coupled to the front slant leg element by a pin 29 and heading toward the rear fixing portion 1R. On the other hand, the ascending oblique leg portion 3B can be integrated with the front end portion of the rear oblique leg element 3R.

  As shown in FIG. 5, the continuous carbon fiber reinforced laminate-structure press-molded resin body 18 is a hairpin-shaped molded product that bends around the front cross member 6 or the back cross member 7 and is arranged in a single row or in two rows in parallel. Is done.

  The vicinity of the tip of the flange portion 17 of the hairpin-shaped molded product forming the composite rear leg 3 is molded in the shape of an arrowhead having only one hypotenuse.

  As shown in FIG. 9, the composite front legs 2 are arranged in two rows in parallel, and are closely integrated at the front fixing portion 1 </ b> F and a portion adjacent thereto to enhance lateral rigidity.

  As shown in FIG. 1, the flange portion 17 in the vicinity of the front fixing portion of the front leg 2 has an arc shape centered on the rear fixing portion 1 </ b> R on both the front surface and the rear surface.

  As shown in FIG. 9C, the flange portion 17 in the vicinity of the front fixing portion of the front leg is gradually reduced toward the fixing portion, so that the delamination fracture is easily given.

  As shown in FIG. 9B, the flange portion 17 whose thickness is gradually reduced toward the fixing portion 1F is provided with a taper 28 having an arrowhead shape in a plan view, and the stress is increased toward the tip.

  Any of the above-described leg structure forming methods can be used to produce a composite vehicle seat.

  The leg structure is composed of a composite front leg and a composite rear leg, so the weight of the seat is reduced, thus reducing the weight of the fuselage, which increases the payload, the cruising range, Contributes to shortening the takeoff and landing distance. The front leg extends downward from the front cross member that supports the seat and the adjacent seat directly under the front edge of the seat surface, and the rear leg is a downward slant leg part from the front cross member toward the rear fixing part, and approximately halfway between the down slant leg part. Since it is formed with up-tilted leg portions extending from the part toward the rear cross member, the shear and moment acting on each part of the leg structure are reduced, for example, compared to the inverted N type, and the lightweight and rigid leg by the truss structure Realize the structure.

  Both the front leg and the rear leg have an I-shaped structure in which the web part bearing the shear load is arranged in the YZ plane, and the full width or one side of the flange part that bears the tensile / compression axial force and enhances the rigidity is provided. Since a continuous carbon fiber reinforced laminate-formed press-molded resin body that functions as a reinforcing bar is arranged in the web part and a part of the web part, the remaining area in the flange part and the remaining area in the web part are set as compound resin for injection molding Thus, a leg structure in which a rigid web portion and a flange portion are formed by fusing the laminate-formed press-molded resin body and the compound resin body is obtained. Thereby, the production of the composite material of the leg structure is further realized.

  Since the front and rear legs are molded as independent parts, the mold specification conforms to the shape of each part, and the size is smaller than that of molds that produce molded products with integrated reinforcement bars for the front legs and rear legs. Thus, the mold for laminating and the injection mold for forming the web part afterwards are reduced in size. This promotes a reduction in mold production costs. Further, in the autoclave process, an increase in the size of the furnace body can be avoided, and an increase in equipment cost can be suppressed. Further, the time required for molding is greatly reduced.

  The molding of the front leg and the rear leg by the injection compound resin is based on the pressure injection of the compound resin melt into the remaining cavity after the pre-molded continuous carbon fiber reinforced laminate configuration press molding resin body is placed in the mold. At that time, since the injection compound resin body and the laminate-structured press-molded resin body are integrated by resin fusion, compared with the case where the production only by lamination molding or the production only by injection is adopted. In the composite material, the proper position of the appropriate reinforcing material is arranged, and the number of places that cause excessive strength and excessive quality is reduced as much as possible.

  If the downward slant leg part extends directly to the rear fixing part, and the up slant leg part is integrally formed with the down slant leg part at a substantially intermediate part of the down slant leg part, the rear leg will be made into one part, As a result of the leg structure being composed of two parts, only two injection molds are required. Moreover, since the mold cavity of the front leg is linear and the mold cavity of the rear leg remains in an inverted T shape, the injection mold can be kept small.

  Since the composite material front leg and the composite material rear leg are assembled as a seat leg via the front cross member or the rear cross member, the integral structural leg can be formed easily and easily. Adhesion and bolt fastening operations may be performed, and post-processing such as when a metal member is targeted is extremely reduced.

  The forward slant leg part is formed of a front slant leg element connected to the front cross member and a rear slant leg element that is pin-coupled to the front slant leg element and heads toward the rear fixing portion. In the case where it is configured so as to be integrated at the front end portion, the rear leg becomes two parts, but the molding die can be further reduced in size.

  If the continuous carbon fiber reinforced laminate structure press-molded resin body is a hairpin-shaped molded product that bends around the front cross member or the back cross member, and is arranged in a row, it is on the side opposite to the web portion of the flange portion in the I-shaped structure. Reinforcing bars can be arranged over the entire width. If the two rows are arranged in parallel, the reinforcing bars can be arranged near the left edge and the right edge of the flange portion on the side opposite to the web portion. Appropriate reinforcement forms considering the load can be applied.

  If the vicinity of the tip of the flange part of the hairpin-shaped molded product that forms the composite rear leg is molded in the shape of one arrowhead on the hypotenuse, the cross-sectional area of the flange part gradually decreases toward the tip, and other adjacent hairpin shapes It is possible to prevent a sudden change in rigidity that occurs between the flange portion of the molded product and suppress the occurrence of stress concentration.

  The front legs made of composite material are arranged in two rows in parallel. If the front fixing part and the part adjacent thereto are intimately integrated into a pine needle shape, the lateral rigidity is enhanced, which is convenient. Further, even if the shock absorber is attached to the leg end, the reinforcing bars in the proximity state can be integrally removed, and the impact absorber can be prevented from becoming complicated.

  If the front and rear flanges in the vicinity of the front fixing part of the front leg have an arc shape centered on the rear fixing part, the lower end of the front leg always maintains the same posture when absorbing the impact by contracting the front leg. The angle of attack of the shock absorber to the destructive action part is constant. That is, it contributes to stabilization of the function of the shock absorber.

  If the thickness of the flange portion in the vicinity of the front fixing portion of the front leg is gradually decreased toward the fixing portion, a relatively large stress acts at the start of shock absorption, and it is easy to give an opportunity for delamination fracture.

  If the flange, whose thickness is gradually reduced toward the fixing part, is tapered in the shape of an arrowhead in plan view, the cross-sectional area becomes smaller toward the tip, and the stress can be increased gently. . When subjected to a large impact, the front leg is easily damaged and can be started from the flange tip.

  Regardless of the above configuration, the composite vehicle seat obtained by the leg structure molding method can be reduced in weight while having the required strength, making it easy and quick to manufacture, minimizing the number of parts, and manufacturing jig It brings many advantages such as simplification, low cost and easy mass production.

The left side external view of the leg structure employ | adopted with the leg structure shaping | molding method of the vehicle seat made from a composite material which concerns on this invention. It is an example of the aircraft seat, Comprising: (a) is a left view, (b) is a perspective view in the case of being set as a continuous seat. The leg structure and the seat bottom frame, where (a) is a normal wearing state diagram, and (b) is a state diagram in which a large deceleration force acts to absorb an impact at the lower end of the front leg. It is an I-shaped structure for front legs and rear legs, wherein (a) is a perspective view showing a partial width arrangement on a flange portion of a laminated press-formed product, and (b) is a perspective view showing a full width arrangement on a flange portion. . The arrangement | positioning figure in the previous step of the combination for every site | part of a lamination structure press molding product. It is the combination arrangement | positioning for every site | part of a laminated structure press-formed product, Comprising: (a) is a perspective view for front legs, (b) is a perspective view for rear legs. The left side external view of the injection molding product of the front leg and the injection molding product of the rear leg. (A) is a combination perspective view of a laminate-structured press-molded product incorporated in an injection-molded product, and (b) is a perspective view of a laminate-structured press-molded product in which an end portion of a front leg molded product is subjected to easy breakage treatment. It is a combination of laminate-formed press-formed products on the front legs, (a) is a front view of the basic shape, (b) is a front view of an improved product subjected to shock absorption facilitating treatment, and (c) is a side view of (b). Fig. 4 is a transition diagram of shock absorption and flange peeling and bending. The left side external view of the leg structure provided with a different rear leg. In the arrangement | positioning in the front | former stage of the combination for every site | part of the laminated structure press molded goods in the case of a different back leg, (a) is a perspective view for front legs, (b) is a perspective view for back legs. The combination perspective view of the different lamination composition press molding goods built in the injection molding goods. The left side external view of a shock absorber. The disassembled perspective view when making a front leg lower end part face an impact-absorbing tool. It is an impact-absorbing tool and a flange part bending mechanism, Comprising: (a) is sectional drawing which shows the damage mechanism of a web part, (b) is sectional drawing which shows the bending mechanism of a flange part. (A) is a load action figure in the case of an N-type leg, (b) is a load action figure in the case of an inverted N-type leg.

  Hereinafter, a method for forming a leg structure of a composite vehicle seat according to the present invention and a composite vehicle seat manufactured by the method will be described in detail with reference to the drawings. FIG. 2A shows a front leg 2 that is in a substantially vertical state and reaches a front fixing portion 1F (a portion that is also fixed to a front floor contact portion, which is fixed by an anchor (not shown)) on the floor. It is an example of a leg structure 5 of a vehicle seat 4 provided with a rear leg 3 that faces a rear fixing part 1R (a part fixed by an anchor or the like not shown in the rear floor contact part).

  As shown in FIG. 2B, the leg structure 5 includes a front cross member 6 that supports the own seat 4M and the adjacent seat 4N directly below the front edge of each seating surface 4S (see FIG. 2A). A composite front leg 2 extending downward from the front beam; a composite down sloping leg portion 3A that slopes downward from the front cross member 6 toward the rear fixing portion 1R; and the down sloping leg. Ascending leg portion 3B extending upward toward the rear side member 7 (also referred to as a rear beam) that tilts upward from substantially the middle part of the portion and supports the own seat 4M and the adjacent seat 4N directly below the rear edge of the seating surface 4S. And a rear leg 3 made of a composite material (see also (a) of the figure). Both the front leg and rear leg composite materials are made of carbon fiber reinforced thermoplastic resin. For example, PPS resin (polyphenylene sulfide resin) is used as a composite material. It has high impact resistance, fatigue characteristics, long-term heat resistance, chemical resistance and self-extinguishing properties, and its melting point is about 280 ° C., which is suitable for hybrid molding described later in the present invention. It is.

  As shown in FIG. 2A, the rear leg 3 is in the form of a slanted leg. Therefore, the rear leg 3 is hardly restricted by the front and rear dimensions of the seating surface 4S, and the front and rear intervals of the fixing portions 1F and 1R are easily increased. . The front beam 6 and the rear beam 7 are pipe-shaped and may be made of a light alloy. However, if the composite material has a cylindrical structure, weight reduction is further promoted. Incidentally, 8 is a backrest, 9 is an armrest, and 10 is a baggage bar.

  In this example, the descending oblique leg portion 3A extends directly to the rear fixing portion 1R, and the ascending oblique leg portion 3B is integrally formed with the descending oblique leg portion 3A at a substantially intermediate portion of the descending oblique leg portion 3A. Therefore, the rear leg 3 is made into one part, and the leg structure 5 is composed of two parts of the front leg and the rear leg, and two types of injection molds to be described later are completed. Moreover, the front leg mold cavity (not shown) is substantially linear, and the rear leg mold cavity (not shown) remains in an inverted T-shape, so that the fluidity during injection is good, The injection mold is not bulky and has good handling properties. As shown in FIG. 3A, the fixing parts 1F and 1R are provided on a seat track 11 and a spreader 12 laid on the floor, or are directly disposed on the floor surface. It is. Since the leg structure 5 described here is not integrated with the front-rear beam that bridges the front cross member 6 and the rear cross member 7 described above, an increase in the size of the mold is eventually avoided. I will touch a little on this point next.

  As described above, the composite front leg 2 and the composite rear leg 3 are assembled as an integral structural leg via the front cross member 6 or the rear cross member 7 as shown in FIG. . This is also shown in FIG. 1, and the leg structure 5 can be assembled easily and easily. Bonding with each cross member, bolting operation of the seat track fitting 13 may be performed at the fixing portion, and there is an advantage that the post-processing steps required for a welding structure or the like for a leg made of a metal member are extremely reduced. is there. Incidentally, it is not a composite molded product integrated with a longitudinal beam (a member corresponding to reference numeral 14 described below) for bridging the front cross member 6 and the back cross member 7, but the large size of the mold. Care has been taken to avoid conversion. That is, the front cross member 6 and the back cross member 7 are cross-linked and integrated in the front-rear direction by a separate material such as the seat bottom frame 14 (see FIG. 3A).

Each of the front legs 2 and the rear legs 3 has a web portion 16 that bears a shear load when the left and right sides of the seat 4 are in the X direction, the front and rear are in the Y direction, and the top and bottom are in the Z direction (see FIG. 2B). Is an I-shaped structure as shown in FIG. Continuous carbon fiber reinforced laminate construction press molding over the entire width or part of the non-web portion side of the flange portion 17 (located in a vertical plane extending in the left-right direction of the seat) that bears tension and compression axial force and enhances rigidity A resin body 18 is disposed. In addition, the cross section of the molded resin body is displayed darkly, FIG. 4A is a partial one that exists in parallel on the left and right, and extends to the entire width of the flange portion 17 in FIG. The remaining area in the flange portion 17 and the web portion 16 (both cross sections are displayed thinly) are formed by injecting and solidifying compound resin. That is, as shown in FIG. 5, press-formed preforms 2P ₁ , 2P ₂ , 3P ₁ , 3P ₂ , 3P ₃ reinforced by lamination of continuous fibers are manufactured in advance. In the case of the front leg 2, the preforms 2P ₁ and 2P ₂ are combined and placed in a mold (not shown) as shown in FIG. 6A, and in the case of the rear leg 3, the preforms 3P ₁ , 3P ₂ , 3P ₃ are combined and placed in a mold (not shown) as shown in FIG. The compound resin is injected so as to form the web part while filling the back portion of the preform product, and the solidified molding is performed to integrate the laminate-structured press-molded resin body 18 and the injected compound resin body 19 as shown in FIG. The front leg 2 and the rear leg 3 are shaped with the rib 20.

  Therefore, each leg becomes a shaped article that has undergone a hybrid molding method including a lamination molding method of a reinforced plastic molding material in which a continuous fiber as a reinforcing member is impregnated with a thermoplastic resin, and a compound resin injection molding method. This hybrid molding method eliminates the need for large auto graves and long-time curing, thereby speeding up mass production. In more detail, the main component of the strength of the flange portion 17 is the carbon fiber reinforced PPS resin which has already been mentioned, and the fiber is made of a unidirectional reinforcement material (UD material uni direction) or a woven material (cloth). The proof strength of the flange portion is high. In addition, at the time of pressure injection of the compound resin melt, the injection compound resin body 19 and the laminate-structured press-molded resin body 18 are highly integrated with each other due to mutual fusion of the respective resins, and are integrated without boundaries. The

As shown in FIG. 5, the partial parts obtained by laminating the laminate-formed press molding are the front leg 2, the rear fixing part side of the descending oblique leg part 3 </ b> A of the rear leg 3, and the ascending oblique leg part 3 </ b> B. Is the front cross member side of the downward sloping leg portion 3A of the rear leg 3. That is, the press-molded preform 3P ₁ is for the full width structure, and the press-molded preforms 2P ₁ , 2P ₂ , 3P ₂ , 3P ₃ are for the partial width structure. Incidentally, the preforms 2P ₁ and 2P ₂ have symmetrical bending as can be seen from FIG. 9, which will be described later, and _two of the preform products 3P ₂ have a tapered portion at the tip (an arrowhead-like portion 23 described later). ) except same shape article, two preforms product 3-Way ₃ are the same shape products.

The press-molded preform by the laminate-structured press-molded resin body 18 is a hairpin-shaped molded product that bends around the front cross member 6 or the back cross member 7 and the pin hole portion 22 for fastening the rear fixing bracket. Yes. In addition, even if it is a single-row arrangement or a two-row arrangement that is distributed closer to the left edge and the right edge of the flange portion 17 on the side opposite to the web portion, the number of layers is changed in consideration of the load and the like. It can be used as a reinforcing bar. Immediately before injection molding for shaping the front leg 2 and rear leg 3 of the leg structure 5 by these, the arrangement is as shown in FIG. 6, and the front leg and rear leg after injection molding have the appearance as shown in FIG. Become. Incidentally, as shown in FIG. 8 (a), In the front leg 2 upper half is a two-row separation arrangement of the preform article 2P _1, 2P _2, is the lower half of the two rows coalescing arrangement . This figure shows a full view of the reinforcing bars when assembled as a leg structure.

  The vicinity of the front end of each press-molded preform in the flange portion 17 of the hairpin-shaped molded product that forms the composite rear leg 3 is formed into an arrowhead shape with only one hypotenuse as shown in FIG. This arrowhead portion 23 gradually reduces the cross-sectional area of the flange portion 17 toward the tip, suppresses sudden changes in rigidity that occur between other adjacent hairpin-shaped molded products, and prevents the occurrence of stress concentration. Is intended.

  As shown in FIG. 6, the front legs 2 made of a composite material are arranged in two rows in parallel, and are closely integrated at the front fixing portion 1F and a portion close to the front fixing portion 1F. That is, as shown in FIGS. 8 (a) and 9 (a), the left-right rigidity is improved by forming a V shape or a pine needle shape. Further, as will be described later, even when the shock absorber 25 (see FIG. 1) is attached to the leg end, the reinforcing bars formed by the laminate-structured press-molded resin body 18 in the proximity state are integrally removed. It is also possible to reduce the complexity of the structure of the shock absorber 25.

Returning to FIG. 1, the flange portion 17a in the vicinity of the front fixing portion 1F of the front leg 2 has an arc shape with radii r ₁ and r ₂ centered on the rear fixing portion 1R. When the seat is about to fall forward during sudden deceleration, the impact is absorbed by shortening the length of the front leg 2. At this time, the circular arc portion 26 keeps the lower end of the front leg 2 in a constant posture such as a right angle with respect to the breaking action portion of the shock absorber 25 so that the certainty of the shock absorbing action can be increased. . When the compound resin is cured, it is relatively brittle, and the web portion 16 is instantaneously scattered by the impact force. However, the absorption of the impact is achieved by bending deformation starting from fiber breakage and delamination of the CFRP flange. Considering the impact absorbing action in this way, it can be seen that the use of a leg structure as a composite material is extremely convenient.

  By the way, as shown in FIG.8 (b), the thickness of the lower end part of the flange part 17 of the front leg 2 is gradually reduced toward the fixing | fixed part 1F, and it is good to make it easy to give the trigger of fiber destruction and delamination. This thickness gradually decreasing portion 27 is advantageous in that a large stress can be applied at the start of shock absorption. Furthermore, the flange portion 17 whose thickness is gradually reduced toward the fixing portion 1F is also provided with a taper 28 having a shape of an arrowhead in a plan view, and the stress acting on the tip can be further increased easily. Since the cross-sectional area becomes smaller at the tip, the gentle increase in stress promotes the fail-safe effect and behavior of the front legs 2 and is very convenient for starting from the flange tip.

  By sharpening the tip in both the plane direction and the plate thickness direction in this way, the breakage from the flange tip is made even smoother. FIG. 3A shows a state of the seat in a normal state, and FIG. 3B shows a state in which the front leg 2 is contracted. Even if it does not seem that the inclination of the seat surface is large, the shock absorbing effect is large. As can be seen from FIGS. 10A to 10C, the flange portion 17 is peeled off from the front leg, and the front flange portion 17F and the rear flange portion 17R are touched later, but are projected as the flange bent strip 17b. Behaves like Since the appearance is in the Y direction of the seat, it is possible to minimize the possibility of heading to his / her legs and legs.

  By the way, as shown in FIG. 11, the forward inclined leg portion 3A is connected to the front lateral member 6 and the front inclined leg element 3F is connected to the front inclined leg element by a pin 29, and the rear inclined leg is directed to the rear fixing portion 1R. It is also possible to form the rear leg 3 in such a manner that the ascending sloping leg portion 3B is integrally formed at the front end portion of the rear slanting leg element 3R. In this case, the rear leg 3 is divided into two parts, ie, a straight link of the front oblique leg element 3F, and a "<" shaped link 3M composed of the rear oblique leg element 3R and the upward oblique leg portion 3B. On the other hand, the size of the molding die can be further reduced. Needless to say, no moment is generated in the pin connecting portion, and the beam rigidity required for the front oblique leg element 3F can be kept low.

FIG. 12 shows the arrangement of the press-molded preforms 3Q ₁ , 3Q ₂ , 3Q ₃ , 3Q ₄ , 3Q ₅ by continuous fiber lamination in the case of the configuration of FIG. 11 and the case of FIG. 6 (a). An integrated product of preform products 2P ₁ and 2P ₂ for the front legs is shown. A perspective view of the laminated press-formed product built in the injection-molded product is shown in FIG. 13 similar to FIG. 8 (a). According to any of the configurations described above, the composite vehicle seat manufactured by the leg structure molding method according to the present invention can be reduced in weight while having the required strength, and can be manufactured easily and quickly. There are many advantages such as minimization of manufacturing, simplification and cost reduction of production jigs, and ease of mass production.

  As can be seen from the description of each embodiment described above, in the composite material vehicle seat to which the front leg mounting shock absorbing device of the present invention is applied, the leg structure is a composite material (carbon fiber reinforced thermoplastic composite material) front leg. Since the rear seats are made of composite material, the weight of the seat can be reduced. Therefore, the weight reduction of the fuselage can increase the payload, increase the cruising range, and shorten the take-off and landing distance. The front leg extends downward from the front cross member that supports the seat and the adjacent seat directly under the front edge of the seat surface, and the rear leg is a downward slant leg part from the front cross member toward the rear fixing part, and approximately halfway between the down slant leg part. Since it is formed with an uphill slant leg portion extending from the part toward the rear lateral member, shear and moment acting on each part of the leg structure are reduced, for example, compared to the inverted N type. By the way, the flange portion includes a continuous carbon fiber reinforced laminate-formed press-molded resin body, so that sufficient force against axial force such as tension and compression is secured. In addition, since the rear leg is in an oblique form, it is less restricted by the front and rear dimensions of the seating surface, and the interval between the fixing portions can be easily increased.

  Both the front leg and the rear leg have an I-shaped structure in which the web part bearing the shear load is arranged in the YZ plane, and the full width or one side of the flange part that bears the tensile / compression axial force and enhances the rigidity is provided. A continuous carbon fiber reinforced laminate-formed press-molded resin body that functions as a reinforcing bar is arranged in the part, and the remaining area and web part in the flange part are set as a compound resin body for injection molding. A leg structure having a rigid web portion and a flange portion formed by fusion bonding is formed. As a result, the production of the composite material of the leg structure further proceeds, a structure with good strength balance and less mechanical waste is achieved, and the consumption of the molding material is suppressed.

  Since the front and rear legs are molded as independent parts, the mold specification conforms to the shape of each part, and the size is small compared to molds that produce molded products with a reinforcing bar assembly integrated with the front legs and rear legs. Therefore, a mold for reinforcing reinforcement molding is indispensable, but an injection mold for forming the web portion is downsized, and a reduction in mold production cost is promoted. Also, in the autoclave process, an increase in the size of the autoclave can be avoided and an increase in equipment cost can be suppressed. The time required for molding is also greatly reduced (for example, 15 minutes). Compared to a metal leg structure, the number of parts is greatly reduced, and the number of manufacturing steps including assembly can be significantly reduced.

  The molding of the front leg and the rear leg by the injection compound resin is based on the pressure injection of the compound resin melt into the remaining cavity after the pre-molded continuous carbon fiber reinforced laminate press molding resin body is placed in the mold. At that time, the injection compound resin and the continuous carbon fiber reinforced laminate composition press-molding resin are integrated by resin fusion, so if only production by lamination molding or production by injection only is adopted In comparison with the above, the reinforcing material in the composite material is appropriately arranged, and the number of places that cause excessive strength and excessive quality is reduced as much as possible.

  Since the front leg is made of a resin molded product, when a large impact is applied, it is easy to introduce an impact absorbing method and a device therefor that use a breakage or destruction phenomenon in accordance with the fail-safe idea. In other words, since the composite material has an I-shaped structure, it is easy to raise the level of safety by expressing two different shock absorption forms such as breaking at a non-rigid location and deforming at a rigid location. be able to. In addition, it is also possible to mix the laminated structure press-molding resin board in a part of web part. The term "part" means that if there is a web part containing a laminate-formed press-molded resin plate, there is also a web part that does not contain it, and the laminate-formed press-formed resin board is a core material in a cross section with the web part. And is in either or both states in the sense that it is covered with a compound resin. Although not shown, the laminate-structure press-molded resin plate as the core material may be formed in a strip shape, for example. In the part where the web part is destroyed and shock is absorbed, it may be left only as a compound resin, or the number of laminations is reduced in order to interpose the laminate-formed press-molded resin plate as the core material, and the web part and the flange part are separated. It is possible to create intentional strength.

  Incidentally, an example of the shock absorber 25 touched above will be briefly described. FIG. 14 is an enlarged photograph of the corresponding part on the left side surface of the seat, which is made of metal. This is composed of a left half 31 and a right half 32 shown in FIG. 15 that hold the lower end portion of the front leg 2 made of a composite material having a web portion 16 in the YZ plane and having an I-shaped cross section. Holding guides 33A and 33B for fitting the lower ends of the two flange portions 17 located in the ZX plane are provided on both the left half and the right half, and the lower end of the web portion 16 is mounted thereon. The web part crushing surface 34 is formed. The left half body and the right half body are provided with holding tongues 35 and 36 fitted between the flange portions so as to contact the left surface or the right surface of the web portion 16 in correspondence with the web portion 16, and the web portion crushing surface. A waste outlet 37 is formed for discharging web waste 16a from 34 in the X direction. Under the holding guides 33A and 33B, a turning surface 38 for bending the flange portion 17 after losing the integrity with the web portion 16 and a turned flange bent strip 17b are divided into two in the Y direction. A discharge port 39 for discharging is provided. FIGS. 16A and 16B show these configurations in different cross sections, and the respective functional parts are grasped.

  Although detailed explanation of the shock absorption behavior is omitted, it can be deformed as shown in FIGS. 10 (a) to 10 (c). In this behavior, the web portion is preceded by crushing or crushing. This is because the web part made of compound resin is somewhat brittle and is easily broken when subjected to a predetermined impact or more. The flange portion is strong because there is a continuous carbon fiber reinforced laminate-formed press-molding resin, and even if the compound resin that forms part of the flange portion collapses, the fiber reinforced resin laminate is not severely destroyed. Therefore, as shown in FIG. 10, some kind of deformation is caused with the laminate. However, since it is a laminate, delamination occurs and the deformation continues, and the impact received by the passenger is moderated to some extent.

  The leg structure and the leg structure molding method according to the present invention described above have been described by taking an aircraft seat as an example. Nowadays, any vehicle is required to be reduced in weight, and it goes without saying that the present invention can be applied to and applied to seats of various vehicles by utilizing its configuration.

DESCRIPTION OF SYMBOLS 1F ... Front fixing part, 1R ... Back fixing part, 2 ... Front leg, 3 ... Rear leg, 3A ... Down slant leg part, 3B ... Up slant leg part, 3F ... Front slant leg element, 3R ... Back slant leg element, 4 ... Seat, 4M ... Own seat, 4N ... Next seat, 5 ... Leg structure, 6 ... Front cross member (front beam), 7 ... Back cross member (rear beam), 16 ... Web part, 17 ... Flange part, 18 ... Continuous laminate structure press molded resin body of carbon fiber reinforced, 19 ... compound resin material, 23 ... arrowhead portion, 27 ... decreasing portion, 28 ... taper, 29 ... pin, r _1, r ₂ ... flange portion in the vicinity of the front fixing part The radius of the arc.

Claims (11)

In the vehicle seat leg structure manufacturing method, a front leg that is in a substantially vertical state and is provided with a front leg that reaches the front fixing part of the floor, and a rear leg that is directed downward toward the rear fixing part is provided.
The leg structure includes a composite front leg that extends downward from a front cross member that supports the seat and the adjacent seat directly below the front edge of the seat, and a composite down slant leg that slopes backward from the front cross member toward the rear fixing portion. And an upward inclined leg portion extending toward the rear lateral member that supports the own seat and the adjacent seat immediately below the rear edge of the seating surface. With a material rear leg,
Each of the composite front legs and rear legs has an I-shaped structure in which a web portion bearing a shear load is arranged in the YZ plane when the left and right sides of the seat are in the X direction, the front and rear are in the Y direction, and the top and bottom are in the Z direction. A laminate-structured press-molded resin body reinforced with continuous carbon fiber is provided on the entire width or part of the web part on the flange part that bears tension and compression axial force and enhances rigidity, and part of the web part. Arranged, the remaining area in the flange part and the remaining area in the web part is a compound resin body of injection molding,
Molding with the injection compound resin is performed by pressure injection of the compound resin melt into the remaining cavity after the previously formed laminate-formed press-molded resin body is placed in the mold, and at that time, the injection compound A leg structure molding method for a vehicle seat made of a composite material, characterized in that the resin body and the laminate-structured press-molded resin body are integrated by resin fusion.   The down sloping leg portion extends directly to the rear fixing portion, and the up sloping leg portion is integrally formed with the down sloping leg portion at a substantially intermediate portion of the down sloping leg portion. A composite leg structure for vehicle seats.   3. The composite vehicle seat according to claim 2, wherein the composite front leg and the composite rear leg are assembled as an integral structural leg via the front cross member or the rear cross member. 4. Leg structure molding method.   The descending oblique leg portion is formed of a forward oblique leg element connected to the front cross member and a backward oblique leg element that is pin-connected to the forward oblique leg element and heads toward a rear fixing portion, and the upward oblique leg portion is 2. The method for forming a leg structure of a composite vehicle seat according to claim 1, wherein the leg part is integrated at a front end portion of the rear oblique leg element.   The laminate-formed press-molded resin body is a hairpin-shaped molded product that bends around the front cross member or the back cross member, and is arranged in one row or in two rows in parallel. A composite leg structure for vehicle seats.   6. The composite material vehicle according to claim 5, wherein the vicinity of the tip of the flange portion of the hairpin-shaped molded product forming the composite material rear leg is formed in an arrowhead shape having only one hypotenuse. Seat leg structure molding method.   The composite material front legs are arranged in parallel in the two rows, and are closely integrated at the front fixing portion and a portion adjacent thereto to enhance lateral rigidity. Leg structure forming method for composite vehicle seats.   6. The legs of a composite vehicle seat according to claim 5, wherein the flange portion in the vicinity of the front fixing portion of the front leg has an arc shape centering on the rear fixing portion on both the front surface and the rear surface. Structural molding method.   6. The vehicle for a composite material according to claim 5, wherein the flange portion of the front leg near the front fixing portion is gradually reduced in thickness toward the fixing portion, and is easily caused to cause delamination fracture. Seat leg structure molding method.   10. The flange portion, whose thickness is gradually reduced toward the fixing portion, is provided with a taper in the shape of an arrowhead in a plan view, and is easily accompanied by an increase in stress toward the tip. Leg structure forming method for composite vehicle seats.   A vehicle seat made of a composite material manufactured by the leg structure molding method according to any one of claims 1 to 10.