JP2000313081A - Reinforcing material for urethane foam molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate the damage caused by a coil spring or the like as a reinforcing material for urethane foam molding and to provide rigidity to impart tension to cushioning properties, by integrating one or more nonwoven fabric layer and a reticulated substrate layer by a needle punching method or a quilting method to provide air permeability thereto. SOLUTION: Nonwoven fabric layers with a predetermined basis wt. formed by opening polyester fibers with a predetermined thickness and forming them into a web form are laminated to both surfaces of a reticulated substrate layer with a predetermined basis wt. wherein split webs and slit webs 11 are laminated in warp and weft directions. After lamination, all of layers are entangled and integrated by needle punching to obtain a reinforcing material for urethane foaming having a three-layered structure. This reinforcing material is set to a mold for foam molding and a foamable urethane resin is added to the mold to perform foam molding. By this constitution, the reinforcing material for urethane foaming is thin, excellent in flatness and reinforcing effect, and prevents that foamed urethane exudes to a surface at a time of molding to form cured matter. The unpleasant noise caused by the friction between urethane foamed cured matter and a coil spring material is prevented and excellent rigidity, durability and a good seating feeling can be imparted.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforcing material for urethane foam molding, and more particularly, to a foam material having sufficient rigidity in a surface structure thereof, for example, when used as a reinforcing material for a cushion material of a seat for a seat. When molding, urethane foam oozes out on the surface of the molded product,
The present invention relates to a urethane foam molding reinforcing material that does not generate abnormal noise due to friction with a metal such as a spring.

[0002]

2. Description of the Related Art As shown in FIG. 1, for example, as shown in FIG.
The urethane layer 3 is provided so as not to be damaged by the pressing force of the above and to have rigidity and to have cushioning.
The reinforcement member 2 is attached to the bottom of the. In the past, slab urethane was installed on the wall surface of a foaming pot as such a reinforcing material 2, and a cold gauze was installed inside the slab urethane, and a urethane liquid was injected, followed by foaming by heating and pressing.

[0003] In order to improve the rigidity shortage in this method, a thin dense layer having a basis weight of 10 to 30 g / m ^2, made of a nonwoven fabric formed by integrating the bulky layer in the coarse of basis weight 40 to 100 g / m ² Reinforcement base cloth for urethane foam molding
No. 2-26193), and furthermore, a basis weight of 110 to 80.
0 g / m ² , 1 to 16 denier high-weight nonwoven fabric (Japanese Unexamined Patent Publication No. 2-258332), a base layer made of the above-mentioned high-weight nonwoven fabric, and a reinforcing coating layer made of a fiber aggregate or the like on one surface thereof. Reinforcing material for foam molding (JP-A-4-14140)
No. 5), a reinforcing material having a base material layer made of a high-weight nonwoven fabric and a reinforcing coating material layer made of a low-weight nonwoven fabric (JP-A-5-57)
No. 827), a bulky substrate layer of 2 to 20 denier and 2 to 1 denier.
Provided is a reinforcing material made of a thin and dense nonwoven fabric of 0 denier (Japanese Patent Application Laid-Open No. 6-136651), which provides rigidity of a foamed molded product and a cured product caused by seepage hardening of a foaming resin liquid onto the surface of the reinforcing material. It is an object of the present invention to prevent the generation of abnormal noise due to friction between a metal member and a holding fitting or the like. However, in the method using the reinforcing material in which the nonwoven fabrics are laminated as described above, there are problems that the reinforcing effect is insufficient, and the thickness is increased because the bulky nonwoven fabrics are laminated.

Further, in order to prevent the generation of friction noise with the sheet frame or the like of the cured resin oozing out of the above-mentioned reinforcing material, a non-breathable plastic film is adhered to a breathable reinforcing material such as coarse felt to form a foam material. (Japanese Unexamined Patent Publication No. Hei 5-138772), a method using a composite sheet comprising a woven fabric composed of an elastomer film containing an ethylene-acrylic acid copolymer or the like, polyester fibers and a resin adhesive layer (Japanese Unexamined Patent Publication No. No. 8337) has also been proposed. However, these methods not only impair the air permeability but also prevent the penetration of the resin liquid into the nonwoven fabric layer, so that the nonwoven fabric layer, which is the reinforcing layer, is not impregnated with the resin liquid and does not have sufficient rigidity. In addition, there is a problem that the function as a reinforcing material is reduced.

Further, in a polyethylene terephthalate long-fiber nonwoven fabric having a denier of 5 to 25 denier, a reinforcing material for urethane foam molding having fibers arranged orthogonally under specific conditions and having a basis weight in the range of ²⁰ to 200 g / m ² (JP-A-7-228709)
No.) is provided. According to the present invention, it is pointed out that if the denier is less than 5 deniers, the density of the long-fiber nonwoven fabric increases, causing problems such as poor outgassing during polyurethane foaming and insufficient penetration of the polyurethane resin into the long-fiber nonwoven fabric.

Further, in order to improve urethane barrier properties, noise prevention and moldability, a method of laminating and integrating a bulky nonwoven layer as an upper and lower layer and a dense nonwoven layer as an intermediate layer (Japanese Patent Laid-Open No. 6-171003) and A method has been proposed in which a layer in contact with urethane foam is a dense nonwoven layer and a layer in contact with a coil spring or the like is a bulky nonwoven layer (JP-A-6-171002). In these methods, the basis weight is 20 to 100.
g / m ² and 30 to 200 g / m ² nonwoven fabric porosity 8
7 to 91% and 90 to 94% of the nonwoven fabric are used separately.

[0007]

DISCLOSURE OF THE INVENTION The present invention is an object of the present invention as a reinforcing material for urethane foam molding. For example, when the present invention is used as a cushion material for a vehicle seat or the like, there is no damage by a coil spring attached to a lower portion. The purpose of the present invention is to provide rigidity and to provide cushioning with tension. Further, the above-mentioned conventional method has a problem to be solved in urethane foam molding, which is an effect of preventing a mold air vent hole from being closed. It is an object of the present invention to provide a urethane foam molding reinforcing material having high strength while preventing generation of abnormal noise due to friction with the urethane cured material on the surface of the reinforcing material in contact with the metal.

[0008]

That is, according to the present invention, at least one or more nonwoven fabric layers and a net-like base material layer are made to have air permeability by any of a needle punching method, a thermal lamination method, a stripe lamination method, and a quilting method. And a reinforcing material for urethane foam molding, wherein the reinforcing material is integrated.

In the above-mentioned present invention, it is preferable that the reticulated base material layer is formed of a reticulated base material obtained by laminating or weaving a uniaxially oriented body formed from a thermoplastic resin film so that its orientation axes intersect. .

In addition, the basis weight of the nonwoven fabric layer is 20 to 120 g /
m ² and the nonwoven fabric layer is preferably formed from 1 to 5 denier fibers.

It is preferable that the reticulated base material layer is provided between the two nonwoven fabric layers, and the reticulated base material layer is provided on the most urethane side.

[0012]

FIG. 2 is a view showing a urethane foam molded article using a urethane foam molding reinforcing material 2a of the present invention having a three-layer structure. In FIG. 5a 'indicates a nonwoven fabric layer, and 4a indicates a net-like base material layer provided between the nonwoven fabric layers 5a and 5a'.
FIG. 3 is a view showing a urethane foam molded article using the urethane foam molding reinforcing material 2b of the present invention having a two-layer structure,
In FIG. 3, reference numeral 3 denotes a mold urethane layer, 5b denotes a nonwoven fabric layer, and 4b denotes a reticulated base layer provided on the urethane layer 3 side.

Materials used as the nonwoven fabric layers 5a, 5a 'and 5b include synthetic fibers such as polypropylene, polyester, high-density polyethylene, low-density polyethylene and nylon, regenerated fibers such as rayon, natural fibers such as cotton and composites thereof. Although it is possible to use fibers, the use of polyester fibers is particularly effective.

The reticulated base material layers 4a and 4b are formed of reticulated base materials obtained by laminating or weaving uniaxially oriented bodies formed from a thermoplastic resin film so that their orientation axes intersect. That is, a nonwoven fabric or a woven fabric excellent in reinforcing effect obtained by laminating or configuring a uniaxially oriented body of at least one kind of thermoplastic resin selected from a split web, a slit web and a uniaxially oriented tape so that the orientation axes intersect. Cloth is used. Since the uniaxially oriented body made of this film is flat, the reinforcing material of the present invention can be made thinner and flatter.

The above-mentioned split web may be a single layer. Preferably, at least two or more layers of a multilayer film produced by extrusion such as a multilayer inflation method and a multilayer T-die method are used in a longitudinal (longitudinal) or horizontal direction. This is a uniaxially oriented net-like film that is stretched in the (width direction) and has a number of cracks intermittently in the stretching direction. The slit web is a uniaxially oriented net-like film that is formed in the single-layer or multi-layer film by forming a large number of slits (cuts) in the vertical or horizontal direction and then extending in the slit direction. The uniaxial tape is obtained by uniaxially stretching the single-layer or multilayer film in the longitudinal or transverse direction before and / or after cutting.

More specifically, as the net-like base layers 4a and 4b made of the uniaxially oriented body, for example, a nonwoven fabric obtained by laminating a slit web and thermocompression bonding, a nonwoven fabric obtained by laminating a slit web and thermocompression bonding, and a split web are used. A nonwoven fabric obtained by laminating a slit web and then thermocompression bonding, a nonwoven fabric obtained by laminating a split web or a slit web and a uniaxially oriented tape so that their orientation axes intersect, or a woven fabric woven with a uniaxially oriented tape can be used.

As the non-woven fabric made of a uniaxially oriented body, it is preferable that at least one kind of uniaxially oriented body selected from a split web, a slit web, and a uniaxially oriented tape is laminated so that the orientation axes cross each other as described above. Depending on the application, the layers may be laminated with the orientation being random or in the same direction. In addition, these nonwoven fabrics or woven fabrics can be used as a composite laminate.

The uniaxially oriented body is provided with a second thermoplastic resin layer having a lower melting point than the first thermoplastic resin as an adhesive layer on at least one surface of the crystalline first thermoplastic resin layer. It is desirable that the multi-layer stretched body is formed by stretching.

Examples of the first thermoplastic resin include high- and medium-density polyethylenes, polypropylenes, homopolymers of α-olefins such as polybutene-1, poly-4-methylpentene-1 and polyhexene-1; Examples include polyolefins such as α-olefin copolymers such as ethylene copolymers, polyamides, polyesters, polycarbonates, and polyvinyl alcohols.

The second thermoplastic resin having a lower melting point than the first thermoplastic resin includes high density, medium density and low density polyethylene, linear low density polyethylene, ultra low density polyethylene, ethylene-vinyl acetate copolymer. Ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid ester copolymer such as ethylene-ethyl acrylate copolymer, and ethylene-methacrylic acid such as ethylene-ethyl methacrylate copolymer Examples include acid ester copolymers, ethylene- (maleic acid or its ester) copolymers, propylene-based polymers such as polypropylene and propylene-ethylene copolymers, and polyolefins modified with unsaturated carboxylic acids. Further, a mixture of these resins and other polyolefin-based resins may be used, such as a high-density polyethylene or an ethylene-α-olefin-copolymer or the like in a random copolymer of propylene and ethylene, 1-butene, or the like. What mixed the polyethylene resin etc. is used.

For reasons of manufacturing and for preventing a decrease in strength increased by stretching or rolling of the uniaxially oriented body, the second
The difference between the melting points of the thermoplastic resin and the first thermoplastic resin is preferably at least 5 ° C or more, more preferably in the range of 10 to 50 ° C.

The specific resin composition of the multilayer film includes high-density polyethylene (HDPE) E / low-density polyethylene (LDPE), LDPE / HDPE / LDPE,
HDPE / ethylene-vinyl acetate copolymer (EVA),
EVA / HDPE / EVA, polypropylene (PP) /
Propylene-ethylene copolymer (PEC), PEC / P
P / PEC, polyester (PEs) / copolyester (CPEs), CPEs / PEs / CPEs, and the like.

Next, a specific example of a method for manufacturing a split web and a slit web will be described with reference to the drawings.

FIG. 4A is a partially enlarged perspective view showing an example of a split web which is uniaxially stretched and split in the longitudinal direction. The split web 6 made of a thermoplastic resin is made of a first thermoplastic resin and a second thermoplastic resin having a melting point lower than that of the first thermoplastic resin by using a multilayer inflation method, a multilayer T-die method, or the like. Of a multilayer film having at least two or more layers produced by extrusion molding in the longitudinal direction (length direction) of 1.1 to 15 times, preferably 3 times.
It is drawn 10 to 10 times and split (split processing) using a splitter in the same direction in a zigzag manner.
As a result, the multilayer film becomes a net-like shape, and is further expanded to a predetermined width to form a mesh-like split web 6. The split web 6 is a uniaxially oriented body having strength in the longitudinal direction over the entire width direction. In the figure, 7 is a trunk fiber and 8 is a branch fiber.

FIG. 4B is a partially enlarged perspective view of a portion B in FIG. 4A. In the split web 6, a second thermoplastic resin 10 is laminated on both surfaces of a first thermoplastic resin 9. It has a three-layer structure.

FIG. 5 (A) is a partially enlarged perspective view showing an example of a slit web in which a film is provided with a large number of slits in the transverse direction and then uniaxially stretched in the transverse direction. A slit web 11 made of a thermoplastic resin is formed by forming intermittent slits in a staggered pattern in a lateral direction (width direction), for example, with a hot blade or the like in a portion of the multilayer film except for both ears. A uniaxially oriented body stretched in the transverse direction at an elongation ratio of 1.1 to 15 times, preferably 3 to 10 times, and has strength in the transverse direction. Preferably, the multilayer film is finely oriented by about 1.1 to 3 times in the longitudinal direction by rolling or the like, and then subjected to slit processing in a staggered manner in the horizontal direction with a hot blade, followed by transverse stretching.

FIG. 5B is a partially enlarged perspective view of a portion B in FIG. 5A. The slit web 11 is also provided on both surfaces of the first thermoplastic resin layer 9 with the second thermoplastic resin layer 10. In a three-layer structure.

FIG. 6 is a partially enlarged perspective view showing the uniaxially oriented tape. The uniaxially oriented tape 12 made of a thermoplastic resin is made of a first thermoplastic resin and a second thermoplastic resin having a melting point lower than that of the first thermoplastic resin, using a multilayer inflation method and a multilayer T-die method. Before and / or after cutting, at least two or more multilayer films produced by extrusion molding are uniaxially oriented in a longitudinal and / or transverse direction at an expansion ratio of 1.1 to 15 times, preferably 3 to 10 times. Into a multilayer stretched tape.

The uniaxially oriented tape 12 also has the first
Second thermoplastic resin layers 10 on both surfaces of the thermoplastic resin layer 9
Are laminated to form a three-layer structure.

FIGS. 7 to 9 show the reticulated base material layer 4 according to the present invention.
It is a specific example of a and 4b. FIG. 7 shows the split web 6
FIG. 3 is a partial plan view of a net-like base material 8 obtained by laminating a slit web 11 and a web so that the orientation axes intersect. FIG. 8 is a partial plan view of a reticulated base material 13 in which two split webs 6 are laminated by way of lamination so that the orientation axes intersect.

FIG. 9 is a partial plan view of a net-like base material 14 in which two sets of uniaxially oriented multilayer tapes 12 are arranged in parallel, and laminated so that their orientation axes intersect. FIG. 10 is a uniaxially oriented multilayer tape. FIG. 2 is a partial perspective view of a net-like base material 15 on which a tape 12 is woven.

The above-mentioned split web-slit web laminated net base material 8, split web-split web laminated net base material 13, uniaxially oriented multilayer tape laminated net base material 14, and uniaxially oriented multilayer tape woven net base material 15 are as follows:
The same net-like base material can be further laminated and used, or different kinds of net-like base materials can be laminated and used as a net-like base material layer in the present invention.

As a specific example of the split web-slit web laminated net base material 8 and the split web-split web laminated net base material 13, “Nisseki Warif” (trade name, registered trademark, manufactured by Nisseki Plast Co., Ltd.) ). Next, urethane foam molding will be briefly described.

In the present invention, a polyurethane foam is a foam made from a diisocyanate and a polyol. Examples of the diisocyanate include m-phenylene diisocyanate, toluene-2,4-diisocyanate, hexamethylene-1,6-diisocyanate, tetramethylene-1,4-diisocyanate, cyclohexane-1,4-diisocyanate, and naphthalene-
1,5-diisocyanate, 1-methoxyphenyl-
2,4-diisocyanate, diphenylmethane-4,
4'-diisocyanate, 4,4'-biphenylene diisocyanate, and the like.

As the polyol, a polyether type such as polyoxypropylene glycol and polyoxypropylene-polyoxyethylene glycol, and a polyester type having adipic acid and ethylene glycol as main components are used. Among them, polyether type is preferred.

The polyurethane foam is prepared by mixing the above-mentioned polyol, a liquid A containing a foaming agent, a catalyst, a cell size modifier and the like and a liquid B mainly containing an isocyanate and the like in a short time. The so-called reaction injection molding method (RI
M).

As a method for producing the urethane foam reinforcing material of the present invention, for example, a nonwoven fabric layer is laminated on one or both sides of a net-like base material layer, and needle punching, thermal lamination (heat treatment), stripe extrusion lamination or A method of imparting air permeability and mechanically bonding or heat-treating the fibers by a usual method such as quilting to fuse them; dispersing the material fibers in an appropriate dispersion medium to prepare a dispersion; An integrated layer of material fibers is formed on the surface of the reticulated base material layer by using a paper forming method, and further subjected to a heat treatment so that the nonwoven fabric layer, which is the integrated layer of the fibers, is made air-permeable on the surface of the reticulated base material layer to be thermally fused. Method (wet method); the material fibers are sprayed and deposited on the reticulated base material layer by air, and heat-treated so that the nonwoven fabric layer is made to accumulate the fibers so that the surface of the reticulated base material layer has air permeability and is heated. And a method for wearing (dry method). The heat treatment may be performed by any method such as, for example, a method of blowing hot air, a method of passing between heat sources, a method of infrared heating, a method of a heater, and a method of a hot roll. Among these, the nonwoven fabric layer and the reticulated base layer are formed using the needle punch method in that the gas generated when urethane foams is passed without impairing the permeability of the reinforcing material and the penetration of the urethane liquid can be controlled. A method of integrating them is preferable.

When a non-woven fabric previously produced in the above-mentioned production method is used for the non-woven fabric layer, it may be produced by any known method as long as it has good urethane barrier properties. Examples include a spun bond method, a needle punch method, a water jet method, and a melt blow method.

FIG. 10 shows an example of a typical flow for producing the reinforcing material 2a for urethane foam molding of the present invention having a three-layer structure. As a preferable material for forming the nonwoven fabric layer, polyester fiber is used. The case where is used will be described.

In FIG. 11, reference numeral 16 denotes a raw cotton hopper made of, for example, a thermoplastic resin fiber, reference numeral 17 denotes a mixing box also serving as a raw material stock, and reference numeral 18 denotes a rough opener for forming the surface nonwoven fabric layer 5a. , 19 are coarse fibrillation openers for forming the other nonwoven fabric layer 5a '. The respective materials which have been coarsely defibrated by the openers 18 and 19 are homogenized in respective card machines 20 and 21 for defibration and web formation, and then the nonwoven fabric layer 5 is formed in the lower line cross layer forming apparatus 22.
a, a web laminate for forming another nonwoven fabric layer 5a 'is formed in a cross-layer forming apparatus 23, and a web laminate for forming another nonwoven fabric layer 5a' is formed. A reticulated base material for forming the reticulated base material layer 4a is supplied from the reticulated base material supply roll 24 between the nonwoven fabric layer 5a and the other nonwoven fabric layer 5a '.

The nonwoven fabric layer 5a and the other nonwoven fabric layer 5
a ′ is compressed by a roll such as a press roll (not shown), and then a nonwoven fabric layer 5 a ′, which is a web laminate below the line, and a reticulated base material layer 4 by a needle punch 25.
The nonwoven fabric layer 5a and the reticulated base material layer 4 are further entangled by the needle punch 26 to form a reinforcing material 27 for urethane foam molding.

The preferred embodiment of the urethane foam molding reinforcing material 2a of the present invention will be further described.

The nonwoven fabric layer 5a and the other nonwoven fabric layer 5
The thickness of the fiber forming a 'is preferably in the range of 1 denier to less than 5 denier. Among the above-mentioned fiber materials, polyester fibers having a thickness of 1 to 3 denier are used as the most preferable ones. If the denier is less than 1 denier, it is difficult to defibrate by a card machine or the like, and it is difficult to uniformly adjust the web. And so on, and 5
If the denier is higher than the denier, the effect of preventing the nonwoven fabric layer 5a or 5a 'from leaking to the surface of the urethane foam molding material becomes insufficient, and as a result, it tends to be difficult to prevent generation of abnormal noise. In the reinforcing material 2a for a urethane foam molded article having a three-layer structure, the basis weight of the nonwoven fabric layers 5 and 5 ′ is preferably in the range of ²⁰ to 120 g / m ² , and the three-layer structure with the reticulated base layer 4a interposed therebetween. It is necessary to have a basis weight that can completely block the urethane liquid so that the urethane does not seep into the mold when it is used. The nonwoven fabric layer 5a and the nonwoven fabric layer 5a 'may be the same or different, but when different materials are used, the nonwoven fabric layer 5' on the side in contact with the mold urethane layer 3 is relatively thin. It is formed of a dense nonwoven fabric and mainly has a role of preventing the passage of urethane liquid. The nonwoven fabric layer 5a on the side in contact with the spring material 1 is formed of a relatively coarse and bulky nonwoven fabric having flexibility. In addition to making the blocking more complete, it is preferable to have a role of improving the cushioning property.

Reinforcing material 2a for urethane foam molding of three-layer structure
Basis weight of the side of the nonwoven fabric layers 5a in contact with the spring member is usually in the range of 30 to 80 g / m ^2, in addition to the case of less than 30 g / m ² is insufficient leakage preventing effect of the urethane solution in, If the cushioning property is poor, and if it exceeds 80 g / m ² , the thickness tends to be large and the ability to follow a curved surface to a mold tends to be poor, which is not preferable.

Mold urethane layer 3 in three-layer structure
The basis weight of the nonwoven fabric layer 5a 'on the side in contact with
g / m ² , and if less than 20 g / m ² , the reticulated base material layer 4a and the nonwoven fabric layer 5 of the urethane foam molding material
a is excessive, and as a result, the leakage to the nonwoven fabric layer 5a surface is insufficiently prevented.
Although it depends on the combination with the nonwoven fabric layer 5a, the thickness is unnecessarily large, which is disadvantageous in cost.

The nonwoven fabric layer 5b in the case of a two-layer structure
In order to fully satisfy the urethane barrier property,
It is better using such an extent that combined non-woven fabric layers 5a and nonwoven layer 5 'in the reinforcing member 2a of a three-layer structure, which is usually in the range of 50 to 120 / m ^2.

Reticulated base material layers 4a and 4 in a three-layer structure
weight per unit area of b is usually ^{10~60g / m 2, 10g / m} 2
If it is less than 60 g, it tends to be difficult to obtain high strength and rigidity as a reinforcing material for urethane foam molding, and if it exceeds 60 g / m ² , it tends to have poor curved surface followability.

The basis weight of the nonwoven fabric layer 5 forming the reinforcing material for urethane foam molding having a two-layer structure is usually 30 to 100 g / m ^2.
If it is less than 30 g / m ² , the effect of preventing leakage of the urethane foam molding material is insufficient, and
If it exceeds / m ² , the following of the curved surface tends to deteriorate, which is not preferable.

[0049]

The present invention will be further described with reference to the following examples.

A nonwoven fabric layer having a basis weight of 40 g / m ² formed by defibrating and webbing 2 denier polyester fibers is laminated,
Next, a web having a basis weight of 35 g / m ² and a thickness of 0.1 formed by laminating a split web and a slit web in a weft manner as a reticulated base layer.
mm Nisseki Warif HS-T (manufactured by Nisseki Plast Co., Ltd.) is supplied from a separate roll, and at the same time, a nonwoven fabric layer similar to the above nonwoven fabric layer is laminated on the reticulated base material layer and entangled and integrated by needle punch. To obtain a urethane foam reinforcing material having a three-layer structure.

The thus obtained urethane foam reinforcing material is placed in a mold for foam molding, with one nonwoven fabric layer surface facing the mold contact side and the other nonwoven fabric layer surface facing the foamable urethane resin addition side. After setting, a foamable urethane resin was added as usual, and polyurethane foaming was performed under heating and pressure to produce a urethane foam molded article.

When the state of penetration and permeation of the polyurethane resin into the outermost nonwoven fabric layer of the obtained molded article was confirmed, no urethane liquid permeated the nonwoven fabric layer at all. Further, no abnormal noise was generated even in an abnormal noise generation model test in which the nonwoven fabric layer surface was brought into contact with a coiled spring and pressurization and depressurization were repeated.

[0053]

Industrial Applicability The urethane foam reinforcing material of the present invention is thin and excellent in flatness and reinforcing effect, and at the time of molding, the urethane foam does not exude to the surface to form a cured product.
Since abnormal noise due to friction between the urethane foam-cured product and the spring material can be prevented, a vehicle seat or the like having excellent rigidity and durability and good sitting comfort can be obtained.

[Brief description of the drawings]

FIG. 1 is a diagram showing an example of a vehicle seat.

FIG. 2 is a sectional view showing an example of a urethane foam molded article using a urethane foam molding reinforcing material having a three-layer structure.

FIG. 3 is a cross-sectional view showing one example of a urethane foam molded article using a urethane foam molding reinforcing material having a two-layer structure.

FIG. 4 is a diagram showing an example of a split web and a partially enlarged perspective view.

FIG. 5 is a diagram showing an example of a slit web and a partially enlarged perspective view.

FIG. 6 is a partially enlarged perspective view showing a uniaxially oriented tape.

FIG. 7 is a partial plan view of a net-like base material obtained by laminating a split web and a slit web.

FIG. 8 is a partial plan view of a net-like base material obtained by laminating two split webs.

FIG. 9 shows a net-like base material obtained by laminating uniaxially oriented multilayer tapes.

FIG. 10 is a net-like substrate woven with a uniaxially oriented multilayer tape.

FIG. 11 is an example of a flow sheet for producing a reinforcing material for urethane foam molding of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Coil spring 2a, 2b Reinforcement material 3 Mold urethane layer 4a, 4b Reticulated base material layer 5a, 5a ', 5b Nonwoven fabric layer 6 Split web 7 Trunk fiber 8 Branch fiber 9 First thermoplastic resin 10 Second thermoplastic resin 11 Slit web 12 Uniaxially oriented tape 13 Split web-slit web laminated net base material 14 Uniaxially oriented multilayer tape laminated net base material 15 Uniaxially oriented multilayer tape woven net base material 16 Hopper 17 Mixing box 18,19 Rough opener 20,21 Card machine 22, 23 Cross layer forming device 24 Reticulated substrate roll 25, 26 Needle punch 27 Reinforcing material for urethane foam molding 28 Winding roll

Claims (6)

[Claims] At least one or more nonwoven fabric layers and a reticulated base material layer are integrated by providing air permeability by any of a needle punching method, a thermal lamination method, a stripe lamination method, and a quilting method. Urethane foam molding reinforcement. 2. The reticulated base material layer is formed of a reticulated base material obtained by laminating or weaving a uniaxially oriented body formed from a thermoplastic resin film so that its orientation axes intersect. 2. The reinforcing material for urethane foam molding according to 1. 3. The nonwoven fabric layer has a basis weight of 20 to 120 g / m ^2.
The urethane foam molding reinforcing material according to claim 1 or 2, wherein: 4. The reinforcing material for urethane foam molding according to claim 1, wherein the nonwoven fabric layer is formed of 1 to 5 denier fibers. 5. The reinforcing material for urethane foam molding according to claim 1, wherein the reticulated base material layer is provided between two nonwoven fabric layers. 6. The urethane foam molding reinforcing material according to claim 1, wherein the reticulated base material layer is provided closest to the urethane side.