JP2006262991A - Seat pad and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a seat pad with sufficient reinforcing effects and noise preventing effects, capable of being manufactured at lower cost, and a method of manufacturing the same. <P>SOLUTION: The seat pad is made of soft polyurethane foam, and has a base fabric layer at least on the rear side. The base fabric 10 has a three-layer structure consisting of a first outer layer, an intermediate layer and a second outer layer, all of which are made of short-fiber non-woven fabric. The intermediate layer includes heat-sealed fiber, and is a calendered non-woven fabric layer whose Metsuke (weight per unit area) dm is 30-70 g/m<SP>2</SP>. The first and second outer layers are non-woven fabric layers whose Metsukes d1 and d2 are 20-60 g/m<SP>2</SP>dm≥d1, and dm≥d2, respectively. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a seat pad used for a vehicle seat and a method for manufacturing the same.

  As a cushion pad used for a vehicle seat, usually a flexible polyurethane foam molded is used. The seat pad made of such flexible polyurethane foam is inserted metal fittings or hook-and-loop fasteners for mounting the seat material of the seat, increasing the strength on the back side of the pad, or when the seat pad is mounted on the vehicle Flexible polyurethane foam in the molding cavity with a non-woven fabric molded base fabric cut out in a predetermined shape for the purpose of preventing abnormal noise generated by sliding with frame metal fittings and springs It is manufactured by supplying a foaming stock solution composition that forms, foaming and curing in a molding die, and integrating these members.

As such a molding base fabric, it is known to use a coarse felt which is a nonwoven fabric of short fibers (for example, Non-Patent Document 1).
Keiji Iwata, "Polyurethane Resin Handbook" (Nikkan Kogyo Shimbun, 1987), page 177

  However, although the coarse wool felt is relatively low cost and has a predetermined reinforcing effect, the foaming stock solution composition during foaming often penetrates and cures to the back surface, and for such sheets. The pad is not preferable because it becomes a defective product in which abnormal noise is generated when the vehicle is mounted and running.

  As a base fabric that solves such problems, spunbonded nonwoven fabric (trade name Borans) using polyester long fibers in which a layer with a high basis weight is laminated with a layer with a low basis weight is used, but it is expensive. Yes, it cannot meet the demand for cost reduction of seat pads.

  An object of the present invention is to provide a sheet pad that has a sufficient reinforcing effect and an effect of preventing the generation of abnormal noise and can be manufactured at a lower cost, and a method for manufacturing the same.

The sheet pad of the present invention is formed of a flexible polyurethane foam, and has a base fabric layer at least on the back side of the attachment. Each of the base fabrics is a first outer layer, an intermediate layer, and a first layer each made of a short fiber nonwoven fabric. It has a three-layer structure consisting of two outer layers, the intermediate layer is a nonwoven fabric layer containing heat-bonded fibers, calendered basis weight (dm) of 30 to 70 g / m ² , and the basis weight of the first outer layer The amount (d1) and the basis weight (d2) of the second outer layer are nonwoven fabric layers of 20 to 60 g / m ² , respectively, and dm ≧ d1 and dm ≧ d2.

  The sheet pad having such a structure has a sufficient back surface reinforcement, has a sufficient effect of preventing abnormal noise generation, and the base fabric is formed of a short fiber nonwoven fabric. It is a pad for seats.

  The use of a nonwoven fabric with a three-layer structure, which is a polyester short fiber nonwoven fabric with a high basis weight of the intermediate layer and a low basis weight of both outer layers, as a backing material for the pad for the sheet, provides sufficient back surface reinforcement. On the surface side that comes into contact with the liquid foam stock solution composition when it is in contact with the base fabric while being foamed and the foam stock solution composition forming a flexible polyurethane foam is calendered and has high strength per unit area It is presumed that the main reason is that the liquid easily penetrates, and thus adheres well to the base fabric after curing. In addition, sufficient anti-noise generation prevention effect is obtained when the foamed stock solution composition reaches the intermediate layer, the penetration is suppressed by the nonwoven fabric layer on the surface side in contact with the foamed stock solution composition, and the intermediate layer The foamed concentrate composition, which is calendered and has a high basis weight, has a tendency to increase in viscosity due to the progress of the reaction. It is presumed that the non-woven fabric constituting is soft because it is not calendered, and even when the foamed concentrate composition leaches into the intermediate layer, the outer layer prevents contact with the frame or the like.

The sheet pad manufacturing method of the present invention includes a base cloth attaching step for attaching a base cloth to a mold, and a foam stock solution composition of a flexible polyurethane foam is supplied and foam-cured to form a base cloth layer on at least the back side of the attachment. A method for producing a sheet pad having a foaming step as a sheet pad having:
Each of the base fabrics has a three-layer structure composed of a first outer layer, an intermediate layer, and a second outer layer made of a short fiber nonwoven fabric, and the intermediate layer contains heat-sealing fibers and is calendered basis weight (dm ) Is a nonwoven fabric layer of 30 to 70 g / m ² , and the basis weight (d1) of the first outer layer and the basis weight (d2) of the second outer layer are 20 to 60 g / m ² of nonwoven fabric layer, respectively. ≧ d1 and dm ≧ d2.

  By the sheet pad manufacturing method having such a configuration, a sufficient back surface reinforcement is performed, a sufficient noise generation prevention effect can be achieved, and a lower cost sheet pad can be manufactured.

  In the sheet pad manufacturing method described above, it is preferable that dm ≧ d1 = d2.

  With such a configuration, it is not necessary to manufacture the front and back as separate materials, so the seat pad can be manufactured at a lower cost, and because the front and back are the same, generation of defective products due to incorrect use of the front and back Can be avoided.

In the above-described method for producing a pad for a sheet, the base fabric preferably has an air permeability of 150 ml / cm ² / sec or less.

If the air permeability exceeds 150 ml / cm ² / sec, the air permeability is too high, and the foaming stock composition penetrates to the back side, and the sheet pad may generate abnormal noise during use.

  As the fiber material constituting the short fiber nonwoven fabric which is a constituent member of the sheet pad in the present invention, a known base fabric used in the sheet pad can be used without limitation, and in particular, rayon fiber, nylon fiber, polyester Nonwoven fabrics such as fibers and polypropylene fibers are preferably used, and polyester fibers are most preferably used in terms of cost.

  An intermediate | middle layer can be manufactured by processing the short fiber nonwoven fabric containing the short fiber of a well-known heat-fusion fiber with the heated calender. The non-woven fabric having a three-layer structure used for the seat cushion pad of the present invention can be manufactured by laminating the first outer layer, the intermediate layer, and the third outer layer in this order and using the needle punch method or the needle punch method and the calendar processing method in combination. .

  FIG. 1 is a perspective view showing a state in which the base fabric of the present invention is mounted on a molding die in manufacturing a sheet pad. The base cloth 10 is locked and attached to the upper mold 43 of the molding mold 46 in which the upper mold 43 and the lower mold 41 are fixed by a hinge so as to be opened and closed by the locking pins 13 erected on the mold. (Base cloth attachment process). The upper mold 43 to which the base fabric is attached forms a back surface for attaching the seat pad to a vehicle frame or the like. The lower mold 41 is provided with an insert fitting 45 that is an example of another sheet pad constituent member. Other members, such as hook-and-loop fasteners, are provided as necessary. In this state, a predetermined amount of the foamed stock solution composition for forming the flexible polyurethane foam is supplied to the lower mold 41, and the mold is closed to foam and cure the foamed stock solution composition (foaming process). An integrated sheet pad is formed.

  The base fabric 10 is cut into a shape determined according to the shape of a sheet pad manufactured from a continuous sheet-shaped raw fabric, and a necessary portion is sewn so as to have a three-dimensional shape along the shape of the upper mold to be mounted. Formed by.

  Using the molding die shown in FIG. 1, a sheet pad molding experiment was conducted using three types of base fabrics as described in Table 1 for both the Examples and Comparative Examples, and the base fabric of the foaming stock solution composition Evaluation of the presence or absence of permeation into the back surface and the actual production of the seat pad were covered with a skin material and mounted on the vehicle as a seat seat.

The base fabric used was a non-woven fabric (d1 = d2) having the same outer layer (first outer layer, second outer layer) on the front and back sides, and a polyester short polyester having a three-layer structure formed by using both the needle punching method and the calendering method. It is a fiber nonwoven fabric. In Examples 1 to 3, the intermediate layer is calendered. In Comparative Examples 1 to 3, the weight per unit area is the same as that of the example, but the intermediate layer is manufactured without calendering. We used what we did. The basis weight of the nonwoven fabric of the outer layer of the base fabric is 25 g / m ² in Example 1 and Comparative Example 1, and 30 g / m ² in Example 2 and Comparative Example 2, and in Example 3 and Comparative Example 3, It was 45 g / m ² .

The air permeability measured by the fragile method defined in JIS L 1096 is 150 (cm ³ / cm ² / s) for the base fabric of Example 1, 130 for the base fabric of Example 2, and 110 for the base fabric of Example 3. Met.

The foaming stock solution used was composed of 70 parts by weight of a polyol X8802 (Asahi Glass) having a hydroxyl value of 17.4 mgKOH / g, 30 parts by weight of a polymer polyol X9802 (Asahi Glass) having a hydroxyl value of 13.8 mgKOH / g, Ichi Kogyo Seiyaku Co., Ltd.) 3.2 parts by weight, 1.2 parts by weight of B8680 (Gold Schmidt) as the foam stabilizer and 0.3 parts by weight of PRX607, 0.3 parts by weight of triethylenediamine (TEDA) as the catalyst and Kaolinizer No. A polyol component containing 0.2 part by weight of 1 (Kao) and 3.0 parts by weight of water was used by mixing TDI-80 as an isocyanate component so that the NCO / OH ratio was 1.03. The formed flexible polyurethane foam had a density of 55.7 kg / m ³ . The evaluation results are shown in Table 1.

表１の結果より、本発明のシート用パッドは、シート用パッドの車両フレーム取り付け側への発泡原液組成物の浸出がなく、車両用シートとして走行したときの異音発生が効果的に防止されたものであった。

From the results in Table 1, the seat pad of the present invention has no leaching of the foamed stock solution composition to the vehicle frame mounting side of the seat pad, and the generation of abnormal noise when traveling as a vehicle seat is effectively prevented. It was.

The perspective view which showed the state which mounted | wore the composite shaping | molding base fabric with the shaping die

Explanation of symbols

10 Base fabric 46 Mold

Claims (4)

It is formed of a flexible polyurethane foam and has a base fabric layer at least on the back side of the attachment, and the base fabric has a three-layer structure consisting of a first outer layer, an intermediate layer, and a second outer layer, all made of a short fiber nonwoven fabric. The intermediate layer is a non-woven fabric layer containing heat-bonded fibers, calendered basis weight (dm) of 30 to 70 g / m ² , and the first outer layer basis weight (d1) and the second outer layer The weight per unit area (d2) is a nonwoven fabric layer of 20 to 60 g / m ² , and dm ≧ d1 and dm ≧ d2. A sheet having a base cloth attaching process for attaching a base cloth to a mold, and a foaming process for supplying a foamed undiluted composition of a flexible polyurethane foam to be foam-cured to form a pad for a sheet having a base cloth layer at least on the back side A manufacturing method for a pad,
Each of the base fabrics has a three-layer structure composed of a first outer layer, an intermediate layer, and a second outer layer made of a short fiber nonwoven fabric, and the intermediate layer contains heat-sealing fibers and is calendered basis weight (dm ) Is a nonwoven fabric layer of 30 to 70 g / m ² , and the basis weight (d1) of the first outer layer and the basis weight (d2) of the second outer layer are 20 to 60 g / m ² of nonwoven fabric layer, respectively. ≧ d1, dm ≧ d2, and a method for producing a sheet pad.   3. The method for manufacturing a sheet pad according to claim 2, wherein d1 = d2. The said base fabric has air permeability of 150 ml / cm < ² > / sec or less, The manufacturing method of the pad for sheets of Claim 2 or 3 characterized by the above-mentioned.

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