JP2000211048A - Quilting sheet material for automotive cushioning, and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To excellently form an uneven design on the surface material side by a method wherein at least the outer surface side, which is the opposite surface to the surface facing a skin material layer, of an non-woven fabric layer is formed into a hardened surface, in a quilting sheet material formed by laminating and fusion- bonding the non-woven fabric layer onto the rear surface side of the skin material layer. SOLUTION: A non-woven fabric layer 2 delivered from a take-up tube 3 is guided to nip rollers 4 and 5 so as to heat its surface side into a melted state in order to pile up onto the rear surface of a skin material layer, which is delivered from take-up tube 8 and guided to a nip roller 6, for lamination through the pressing with the nip rollers 5 and 6, resulting in being guided to a take-up tube 9 for taking-up under the state of a laminated sheet. Next, the take-up laminated sheet is guided to a roller 10 so as to heat the non-woven fabric layer 2 opposite to the skin material layer 1 side in order to fusion-bonding the fibers of its surface for winding up to a take-up tube 13 through the pressing with rollers 10 and 11. Thus, the skin material layer 1 and the non-woven fabric layer 2 are laminated to each other under the state that the outer surface on the rear surface side of the non-woven fabric side of the non- woven fabric side is turned into a hardened surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

2. Description of the Related Art In recent years, depletion of the earth resources and protection of the natural environment have been particularly demanded, and there is an urgent need worldwide to recycle synthetic resin products and not to pollute or destroy the environment when disposing or burning them. is there. The present invention can also help such a request.

2. Description of the Related Art Conventionally, a cushion sheet material for an automobile has, in order from its surface side, a surface material such as synthetic or natural leather or a cloth vegetated with pile, a urethane layer as an external force buffer, and expansion and contraction of the urethane layer. While following sex
It is composed of three layers of tricot half ground for imparting smoothness during sewing, and the laminated sheet body composed of these three layers is cut and sewn in accordance with the shape of the seat body, and put on the seat body. , A fastener or the like to the seat body.

[0003] That is, the cushion sheet material for automobiles is made of a material different from the material used for the front surface and the material used for the back surface, and which cannot be easily incinerated, such as latex, vinyl chloride or urethane foam. Since these are integrated with each other, it is not easy to separate or divide them, and it is very difficult to recycle and reuse them.

[0004] In order to overcome such problems, attempts have been made to construct all the constituent materials constituting the cushion sheet, for example, from unified fiber products made entirely of polyester resin. In order to eliminate the problem caused by the interposition of the intermediate urethane layer in the conventional cushion sheet material, the present inventors constructed an automobile cushion sheet using a fiber sheet layer made of a nonwoven fabric instead of the urethane layer. In addition, research has been conducted on labor saving and high quality of the cushion sheet manufacturing. (Patent No. 2,843,
No.561)

[0005]

By the way, when a nonwoven fabric layer is used in place of the urethane layer, and a cushion sheet for an automobile from which a tricot half is removed is used, a quilting process is performed in order to form an uneven design on the surface material side. In the case of application, it has been found that even if irregularities are formed on the back surface side of the nonwoven fabric layer, there is a disadvantage that the irregularities are not formed on the intended front surface side. The present invention seeks to eliminate this disadvantage.

[0006]

A first aspect of the present invention is a quilting sheet for an automobile cushion, which is obtained by laminating a nonwoven fabric layer made of a thermoplastic fiber on the back side of a skin material layer of an automobile cushion sheet and fusing and bonding them. In the material, the nonwoven fabric layer is a quilting sheet material for an automobile cushion that can exhibit a quilting processing effect, characterized in that at least the outer layer surface side opposite to the surface facing the skin material layer is a hardened surface. is there. According to a second aspect of the present invention, in the quilting sheet material for an automobile cushion according to the first aspect, the non-woven fabric layer has a heat-sealing fiber, a heat-sealing resin or a heat-sealing fiber non-woven fabric on at least one surface side thereof. A non-woven fabric layer, wherein the non-woven fabric layer is fusion-bonded to the back surface side of the skin material layer by heat fusion of the heat-fused fiber, heat-fused resin or heat-fused fiber non-woven fabric present on one surface side. A quilting sheet material for an automobile cushion, which is capable of exhibiting a quilting processing effect. According to a third aspect of the present invention, in the quilting sheet material for an automobile cushion according to the first or second aspect, on the outer layer side of the nonwoven fabric layer, fibers on a surface are fused and fixed to each other, and the surface is fixed. Is a quilting sheet material for an automobile cushion, which can exhibit a quilting effect, characterized by having a cured surface. According to a fourth aspect of the present invention, at least one surface of the nonwoven fabric layer made of a thermoplastic fiber in which a heat-fused fiber, a heat-fusible resin or a heat-fused fiber nonwoven fabric is present, is coated with a flame burner or an electric heater. For automotive cushions that are directly heated and hot-melt the heat-fused fiber, heat-fused resin or heat-fused fiber non-woven fabric that was present on one side, and then immediately superimposed on the back of the skin material and pressed to bond. In the method for producing a quilted sheet material, the outer surface of the other side of the nonwoven fabric layer is subjected to a curing treatment before the laminating treatment or a curing treatment after the laminating treatment. This is a method for producing a quilting sheet material for an automobile cushion. According to a fifth aspect of the present invention, in the method for manufacturing a quilting sheet material for an automobile cushion according to the fourth aspect, the hardening treatment of the nonwoven fabric layer is performed by using a flame burner or an electric heater on the other outer surface of the nonwoven fabric layer. A method for producing a quilting sheet material for an automobile cushion, which is capable of exhibiting a quilting effect, wherein the heating is performed by directly heating and melting the fibers on the outer surface of the other surface side, melting and bonding the fibers together.

[0007] The present invention is directed to a nonwoven fabric layer made of a thermoplastic fiber which is laminated on the backside of a cushion sheet skin material layer and fused and bonded thereto, at least on the back side of the nonwoven fabric layer (the side opposite to the surface facing the skin layer). By having a cured surface bonded by heat between the fibers, when sewing, unevenness due to the sewing does not appear on the back side of the nonwoven fabric sheet layer, but on the front side of the skin material layer. It has become.

The present inventor has not determined the exact reason at present, but thinks as follows. That is, when the fibers on the back side of the nonwoven fabric layer are not bonded by heat, and the fibers are in a state where they are easily movable with each other, the quilting sewing of the nonwoven fabric layer and the skin material layer in such a state is performed. The sewn portion receives a force directed toward the inside of the skin material and the nonwoven fabric layer, and thereby tends to move in the interior direction. However, compared to the skin material layer, the nonwoven fabric layer moves easily between the fibers, Therefore, the sewn portion on the side of the nonwoven fabric sheet layer is directed toward the inside, and irregularities are formed on the back side of the nonwoven fabric layer side. On the other hand, in the present invention, the back side of the nonwoven fabric layer has a hard mesh-like surface such as a wire mesh by curing and fixing between fibers by heat fusion. Even if the quilting sewing is performed between the nonwoven fabric layer and the skin layer, the sewn portion of the nonwoven fabric layer on the outer surface on the back side resists the force directed inward, and does not move in the inward direction. That is, it is considered that the unevenness is not formed on the outer surface of the back surface side of the nonwoven fabric layer, but formed on the surface material layer.

As the skin material, a skin material conventionally used as a cushion sheet for automobiles can be appropriately used. In the present invention, a nonwoven fabric layer used as a back surface layer of the skin material is taken into consideration, and an adhesive property with the nonwoven fabric layer is taken into consideration. Considering the recyclability, a fabric made of a fibrous material composed of the same polymer as the nonwoven fabric layer is more preferable. For example, when the non-woven fabric layer on the back side uses a non-woven fabric made of polyester fibers, as the skin material layer, if a base fabric in which polyester pile yarns are planted with tufts or the like on a base fabric (fabric) made of polyester fibers is also used, The adhesiveness between the fabrics is good, and it is extremely effective in recycling the laminated fabric.
Needless to say, the skin material may be a fabric having a pile or a fabric having no pile depending on the use or preference.

[0010] The nonwoven fabric layer laminated on the back surface of the skin material layer is a buffer layer that appropriately reduces tension, compression and the like applied to the skin material layer and keeps the skin material layer always in a smooth shape. A main fiber having a melting point or softening point of 2
It is necessary that 10 to 50% by weight of a heat-adhesive fiber having a polymer component at least 0 ° C. or lower as a surface component is contained.

The polymer component exhibiting thermal adhesiveness is not particularly limited as long as it is a thermoplastic polymer satisfying the above-mentioned relationship with the main fiber. However, in consideration of recycling, polyester or polyolefin polymer components are preferably used. You.

If the content of the heat-adhesive fiber is less than 10% by weight, a strong bonding state cannot be provided between the fabrics. Therefore, the content is preferably 20% by weight or more.
On the other hand, when the content of the heat-adhesive fiber exceeds 50% by weight,
The nonwoven fabric layer becomes hard, which is not preferable for the purpose.

The heat-adhesive fiber may be a fiber consisting of a polymer component having the above-mentioned melting point or softening point alone, or a core-sheath type or side-by-side type composite fiber having such a polymer component as at least a surface component. You may.

The lamination of the skin material layer and the nonwoven fabric layer on the back surface thereof is performed by directly heating at least the surface of the latter nonwoven fabric layer containing heat-adhesive fibers using a flame such as a gas burner or an electric heater. At the time when the heat-adhesive fibers are softened and melted, the lamination is completed by lightly pressing the back surface of the skin material layer immediately with, for example, a room temperature or low temperature pressure roll.

It is not necessary to heat the back side of the skin material layer,
Rather, because the back side is at room temperature or low temperature, the molten part is cooled while bonding and at the same time,
Lamination is performed efficiently. For this reason, this bonding method does not perform preliminary heating on the skin material layer,
Conventional bonding process, in which a strong bonding state can be obtained simply by pressing the laminate under relatively low temperature conditions of about room temperature without applying pressure under severe conditions, so that severe heat compression is applied to both fabrics at the time of bonding In the case of a cushion sheet having a pile without the pile falling as seen in the pile product obtained, the cushion sheet has a good appearance and a high commercial value.

Increasing the adhesive strength between the skin material layer and the non-woven fabric layer on the back surface is more preferable for a cushion sheet for automobiles. Alternatively, an adhesive fiber having a low softening point, an adhesive nonwoven fabric, or an adhesive resin powder is temporarily fixed, and then the adhesive fiber, the adhesive nonwoven fabric, or the adhesive resin powder temporarily fixed as described above is applied thereto. By directly heating and melting, stronger adhesion can be achieved.

The adhesive non-woven fabric may be a dry or wet non-woven fabric usually made of fine-grained heat-adhesive fibers, or a melt-blown non-woven fabric made of ultra-fine-grained heat-adhesive fibers. In the case of using a melt-blown non-woven fabric, it is more preferable to use a melt-blown non-woven fabric because the fineness thereof is fine and the dispersion is uniform, so that uniform bonding can be performed by heating and melting.

The object of the present invention is a sheet laminate for automobile cushions by the direct heating method as described above, and the sheet laminate is subjected to a quilting process by sewing to form a layer on the skin material layer. To obtain a quilted sheet material provided with good unevenness due to the quilting. In this case, at least the surface portion of the back side of the nonwoven fabric layer (the side opposite to the surface to be bonded to the skin material layer) has not been subjected to any processing, and the constituent fibers are in a state in which the constituent fibers easily move with each other. As described above, when a nonwoven fabric is subjected to a quilting process, only a concavo-convex pattern is formed on the back surface side of the nonwoven fabric layer, and no concavo-convex pattern is formed on the skin material layer side.

The present invention solves this problem by preventing at least the outer layer surface on the back side of the nonwoven fabric layer from being a hardened surface, thereby preventing the quilted sewing portion from moving toward the inside on the back surface side of the nonwoven fabric layer. And a good uneven pattern on the surface side of the skin material layer.

Here, the means for making at least the outer layer surface on the back side of the nonwoven fabric layer a hardened surface is not only a method of making at least the outer layer surface on the back surface of the nonwoven fabric itself a hardened surface, but also a method of making the hardened surface. This also includes a method of laminating another fabric or the like whose surface stitches and stitches are not loosened on the outer layer surface on the back side of the nonwoven fabric sheet layer at a stage before the quilting sewing process. It is more preferable to use the former means in terms of manufacturing cost.

In the case of the former method, in order to make at least the outer layer surface on the back side of the nonwoven fabric layer a hardened surface, for example, the back layer is directly heated by a burner or an electric heater to melt the fibers on the outer layer surface and bond them together. And then immobilized. In this case, since the nonwoven fabric layer itself is made of thermoplastic fibers, the fibers can be melted and bonded to each other and fixed by the heating means.

FIG. 1 further illustrates the preferred manufacturing method in the above description. That is, in this example, a heat-bondable nonwoven fabric (not shown) is formed on the surface side of the nonwoven fabric layer 2
Temporarily fixed, the back side using the sheet layer as it is,
By a direct heating method on the front side and the back side, a sheet laminate to be subjected to quilting processing is obtained, in which the front side is bonded to the back side of the skin material layer 1 and the outer side is a hardened side. It is an example.

In the figure, a skin material layer 1 is prepared by being wound up by a winding tube 8, and a nonwoven fabric layer 2 having a heat-adhesive fiber temporarily fixed on its surface side is prepared by being wound up by a winding tube 3. Have been. The nonwoven fabric layer 2 is pulled out from the winding tube 3 and guided to nip rollers 4 and 5 via rollers. On the rollers 5, the surface side is directly heated by a gas burner 7 to bring the surface into a molten state and separately. The back surface of the skin material layer 1 drawn out from the winding tube 8 and guided to the nip roller 6 is overlapped, pressed by the nip rollers 5 and 6, bonded while cooling, and guided to the winding tube 9, Winding is performed in the state of a laminated sheet. (As mentioned above, the laminating step of the skin material layer 1 and the nonwoven fabric layer 2) Next, the laminated sheet wound up above is
And the nonwoven fabric layer 2 on the opposite side to the skin material layer 1 side is directly heated by a gas burner 12 so that the fibers on the surface are fused and bonded to each other.
Pressing at 1, cooling, and winding up on the winding tube 13. (The above, the hardened surface forming step on the back surface side of the nonwoven fabric layer 2) By the above process, the skin material layer 1 and the nonwoven fabric fiber sheet layer 2 are laminated, and the outer surface on the back surface side of the nonwoven fabric layer 2 becomes a hardened surface. Thus, an automobile cushion sheet suitable for quilting is obtained. In the above description, an example in which the joining operation of the skin material layer 1 and the nonwoven fabric layer 2 and the operation of forming a hardened surface on the back surface side of the nonwoven fabric layer 2 are generally performed in different steps because of the difference in processing speed. But nip roller 5,
Of course, it is also possible to carry out the continuous operation in which the laminated sheet coming out of 6 is led directly from the nip rollers 5 and 6 to the nip roller 10 without being wound up by the winding tube 9 once.

[0024]

EXAMPLES The present invention will be further described below with reference to examples, but the present invention is not limited to these examples.

Example 1 <Preparation of surface material> Using a three-bar tricot knitting machine, a polyester 150 denier / 72 filament yarn was used as a front yarn, and a polyester 75 was used as a middle yarn and a back yarn.
A full cut fabric with a pile height of 3 mm was made using denier / 24 filament yarn. <Preparation of nonwoven fabric fiber sheet>; 90% of polyester fiber (melting point = 260 ° C.) 15 denier × 64 mm raw cotton as main fiber, low melting point polyester fiber (softening point = 110 ° C.) as heat bonding fiber, 6 denier × 64 mm 1
After mixing with 0%, a web was spun out by a card, and this was subjected to needle punching to produce a nonwoven fabric.

<Fixation of heat-bondable nonwoven fabric>: A melt-blown nonwoven fabric (hereinafter abbreviated as MB) made of a low-melting polyester having an average basis weight of 30 g / m ² is superimposed on one side of the nonwoven fabric, and a needle punch is formed from the MB side. Then, the MB was fixed to the web, and a dry heat treatment was performed at 190 ° C. for 1 minute to obtain a nonwoven fabric having the MB fixed thereto. The nonwoven fabric was wound so that the MB was on the front side, and the basis weight was 280 g / m ² . I got

<Preparation of Laminated Sheet>; The MB-fixed nonwoven fabric obtained and wound up above is pulled out from the winding tube 3 in FIG. 1 and guided to nip rollers 4 and 5 via rollers. Then, the surface MB side is directly heated by the gas burner 7 to make the surface in a molten state, and is separately pulled out from the winding tube 8 and guided to the nip roller 6 to the back surface of the skin material layer 1 (the one having no pile). Surface), pressed with the nip rollers 5 and 6, stuck together while cooling, and wound around a winding tube 9. Next, the wound laminated sheet is pulled out from the winding tube 9 and guided to the nip roller 10 with the back side of the nonwoven fabric (the side on which MB is not fixed) facing upward, and the gas burner 12 is placed on the nip roller 10. Directly heated to melt-bond the fibers on the back side of the nonwoven fabric, immediately led to the nip roller 11, pressed by the nip rollers 10, 11 and allowed to cool, and the laminated sheet having a hardened surface where the back side of the nonwoven fabric was hardened. I got

<Evaluation of final laminated sheet>: The laminated sheet obtained as described above had a good pile yarn standing and excellent surface. The laminated sheet was subjected to a quilting process by sewing. An excellent quilting pattern was formed on the surface side of the material layer where the irregularities were clear and the irregularities were not reduced.

[0029]

According to the present invention, as a cushion sheet material for automobiles, it is possible to adopt a material composition that facilitates the recyclability of the cushion material. It is a quilted sheet material provided, and is highly useful and useful as a cushion sheet material for automobiles.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a method for producing a quilting sheet material of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Skin material layer 2 Nonwoven fabric layer 3 Take-up tube 4 Nip roller 5 Nip roller 6 Nip roller 7 Gas burner 8 Take-up tube 9 Take-up tube 10 Roller 11 Nip roller 12 Gas burner 13 Take-up tube

Claims (5)

[Claims] 1. A quilting sheet material for an automobile cushion obtained by laminating and fusion-bonding a nonwoven fabric layer made of a thermoplastic fiber on the back side of a skin material layer of an automobile cushion sheet, wherein the nonwoven fabric layer is the skin material layer. A quilting sheet material for an automobile cushion capable of exhibiting a quilting effect, characterized in that at least the outer layer surface opposite to the surface opposite to the surface is a hardened surface. 2. The quilting sheet material for an automobile cushion according to claim 1, wherein the non-woven fabric layer is a non-woven fabric layer having a heat-sealing fiber, a heat-sealing resin or a heat-sealing fiber non-woven fabric on at least one surface side thereof. Yes, the non-woven fabric layer,
Quilting characterized by being fused to the back side of the skin material layer by heat fusion of the heat-fused fiber, heat-fused resin or heat-fused fiber non-woven fabric on one surface side Quilting sheet material for automobile cushions that can exhibit processing effects. 3. The quilting sheet material for an automobile cushion according to claim 1, wherein the outer layer surface side of the nonwoven fabric layer is fixed by fusion bonding of fibers on the surface, and the surface is a hardened surface. A quilting sheet material for automobile cushions, which can exhibit a quilting effect. 4. A heat-sealing fiber,
One side of the non-woven fabric layer made of thermoplastic fiber in which a heat-sealing resin or a heat-sealing fiber non-woven fabric is present is heated directly by a flame burner or an electric heater, and the heat-sealing fiber and the heat-sealing are present on the one side. In the method for manufacturing a quilting sheet material for an automobile cushion, in which a resin or a heat-fused fiber nonwoven fabric is hot-melted and immediately laminated and pressed on the back surface of the skin material and bonded, the other outer side surface of the nonwoven fabric layer is A method for producing a quilting sheet material for an automobile cushion capable of exhibiting a quilting effect, wherein a curing treatment is performed in advance by a heating treatment before the bonding treatment or a curing treatment by a heating treatment after the bonding treatment. 5. The method for producing a quilting sheet material for an automobile cushion according to claim 4, wherein the hardening treatment of the nonwoven fabric layer directly heats the other outer surface of the nonwoven fabric layer by a flame burner or an electric heater. And a method of fusing the fibers on the outer surface of the other surface side, fusing and bonding them together, and fixing the fibers.