JP2001046185A - Cushion body and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an easily recyclable cushion body of a three-dimensional mesh structure. SOLUTION: This cushion body 1 includes a mesh cushion material 3 having a three-dimensional random loop mesh structure, and framing wires 4 fixed to the mesh cushion material 3 by clips 5. The mesh cushion material 3 has a three-dimensional mesh structure with an apparent density of 0.005 to 0.2 g/cm3, in which a number of continuous linear elements 2 made from a thermoplastic resin and having a fineness of 300 to 100,000 denier are twisted like loops and have their contacting parts fused together. The clip 5 has a framing wire attaching part, an insertion part consisting of a pair of arms each having a width smaller than the outside diameter of the framing wire 4 and having a pointed end, and a locking part projecting outward from each side of the insertion part and pointed to the framing wire attaching part. The locking part is hooked to a portion of the three-dimensional random loop continuous linear body 2 of the mesh cushion material 3, whereby the framing wires 4 are fixed to the mesh cushion material 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion body suitable for seats mounted on vehicles such as vehicles, ships, and aircraft, or furniture such as sofas and beds, and a method of manufacturing the same.

[0002]

2. Description of the Related Art For example, a cushion member made of urethane foam has been widely used as a cushion body used for a vehicle seat or the like. In order to fix this kind of cushion material to a vehicle body or to cover a skin material on the outside of the cushion material, a frame line made of a metal wire is provided along the peripheral edge of the cushion material. This frame line also has a function of giving the cushion material rigidity.

In the case of a cushioning material using a resin foam such as urethane foam, a frame line is set in a resin foam molding mold, and the frame line is integrated with the resin foam as the resin foam is foamed. . Therefore, the frame line and the resin foam are bonded to each other by the adhesive force of the resin foam.

[0004]

In order to recycle the cushion material, a frame line is formed by the cushion material (resin foam).
Need to be separated from However, when the frame is integrally formed in the resin foam, it is extremely difficult to separate the frame from the resin foam because the frame and the resin foam are firmly adhered to each other.
It takes a lot of time and money to separate them. For this reason, recycling was difficult in practice.

Accordingly, an object of the present invention is to provide an easily recyclable cushion body which can easily separate a cushion material and a frame line, and a method of manufacturing the cushion body.

[0006]

According to a first aspect of the present invention, there is provided a cushion body comprising a thermoplastic resin having a fineness of 3%.
A net-shaped cushion having a three-dimensional net structure having an apparent density of 0.005 to 0.2 g / cm ³ , in which a plurality of continuous linear bodies having a denier of 100 to 100,000 are wound in a loop shape and their contact parts are fused together. Material, a frame line made of metal or synthetic resin to be attached to the mesh cushion material, a clip for fixing the frame line to the mesh cushion material, an insertion portion inserted into the mesh cushion material, and the continuous linear shape. And a clip having a retaining portion that can be hooked on the body.

In the cushion body of the present invention, by inserting the insertion portion of the clip into the mesh-like cushion material, the clip retaining portion is hooked on a part of the three-dimensional random loop of the continuous linear body, and the frame line is fixed. You. At the time of disassembly for recycling, the frame line can be separated from the mesh cushion material by applying a force for peeling the frame line from the mesh cushion material, for example, by breaking the clip.

[0008] An example of the clip includes a frame line attaching portion to be fitted to the frame line, an insertion portion comprising a pair of arms having a narrower width and a sharper end than the frame line attaching portion, A resin clip integrally having a retaining portion protruding outward from both sides of the portion and facing the frame line attaching portion side.

A frame line insertion groove for accommodating the frame line may be formed in the mesh cushion material. The frame line insertion groove extends the frame line from the back surface of the mesh cushion material to, for example,
The depth should be such that it is buried about m. Further, by providing a cover member made of a non-woven fabric or the like covering the frame line on the back surface side of the mesh cushion material, generation of abnormal noise due to contact with the cushion mounting surface may be prevented. To form the frame insertion groove, a thermoplastic continuous linear body constituting the mesh cushion material is pressed by pressing a mold heated to a temperature higher than the softening temperature of the mesh cushion material against the mesh cushion material. Is heated and deformed into a groove shape.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to FIGS. The cushion body 1 shown in FIG.
A net-shaped cushioning material 3 having a three-dimensional net-like structure in which a continuous linear body 2 of 0 denier or more is meandered in a random loop shape and the contact portions of each loop are fused together.
And a frame line 4 provided on the back side of the mesh cushion material 3 and a clip 5 for fixing the frame line 4. The outer surface side of the mesh cushion material 3 is covered with a skin material via a wadding or a layer made of fine fibers having a small wire diameter (not shown). An example of the wire diameter of the continuous linear body 2 is φ1
mm.

The frame line 4 is made of, for example, a steel wire having a wire diameter of 6 mm, and is provided continuously along the periphery of the mesh cushion material 3 over the entire periphery of the mesh cushion material 3 or a part of the periphery in a frame shape. . This frame 4 is the cushion 1
It can be used to lock a bracket on the cushion mounting surface side when attaching to a vehicle body or the like, or to lock a terminal stopping member of the skin material when covering a skin material (not shown). . The frame line 4 also has a function of making the mesh cushion material 3 rigid. This frame line 4 may be made of a synthetic resin.

The frame 4 is fixed to the mesh cushion material 3 by clips 5 provided at a plurality of positions in the longitudinal direction. The clip 5 is made of a synthetic resin such as polyester, for example. As shown in an example in FIG. 2A, the clip 5 is fitted with a frame line attaching portion 5a in a state where the frame line 4 is inserted, and a pair of sharpened tips are formed. An insertion portion 5c including an arm 5b;
A retaining portion 5d protruding outward from both sides of c and facing the frame line attaching portion 5a is integrally formed. By making the width W of the insertion portion 5c narrower than the outer diameter D of the frame line 4, the frame line 4 is easily held.

The clip 5 may have a shape having two or more pairs of retaining portions 5d as shown in FIG. 2 (B). In short, a frame line attaching portion 5a fixed to the frame line 4 and a mesh cushion material 3 and the continuous linear body 2
Any shape having a retaining portion 5d that can be hooked on a part of the three-dimensional random loop described above may be used.

If the apparent density of the mesh cushion material 3 is less than 0.005 g / cm ³ , the resilience will be lost, and it is not suitable as a cushion body. The apparent density is 0.
If it exceeds 2 g / cm ³ , the resilience becomes too strong and the sitting comfort becomes poor, so that it is also unsuitable as a cushion body. More preferred apparent density 0.01 g / cm ³ or more and 0.05 g / cm ³ or less.

On the other hand, if the fineness of the continuous linear body 2 is less than 300 denier, the strength is reduced and the repulsive force is reduced, which is not preferable. If the fineness exceeds 100,000 denier, the number of the continuous linear bodies 2 per unit volume decreases, and the compression characteristics deteriorate. That is, it is 300 denier or more, and preferably 400 denier or more and 100,000 denier or less, and more preferably 500 to 50,000, at which a preferable repulsion force is obtained as a cushion body.
Denier.

As the thermoplastic elastic resin which is the material of the continuous linear body 2, a polyester elastomer, a polyamide elastomer, a polyurethane elastomer, or the like can be used. The polyester elastomer is, for example, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylene diol as a soft segment, or a polyester ether block copolymer having an aliphatic polyester as a soft segment. Examples of the polyamide-based elastomer include those having a hard segment of nylon and a soft segment of polyethylene glycol or polypropylene glycol.

The thermoplastic elastic resin may be combined with a thermoplastic inelastic resin. The thermoplastic inelastic resin is, for example, polyester, polyamide, polyurethane or the like. The combination of the inelastic resin and the thermoplastic elastic resin is preferably a resin of the same type from the viewpoint of recycling use, for example, a combination of a polyester elastomer and a polyester resin, or a polyamide elastomer and a polyamide resin. Or a combination of a polyurethane-based elastomer and a polyurethane-based resin is recommended.

The mesh cushion material 3 is manufactured by a mesh cushion material manufacturing apparatus 10 conceptually shown in FIG. One example of the cushioning material manufacturing apparatus 10 includes an extruder 15 and a nozzle unit 16. The extruder 15 extrudes the thermoplastic elastic resin raw material supplied from the material supply port 17 toward the nozzle part 16 while heating the raw material to a temperature higher by 10 ° C. to 80 ° C. (for example, a temperature higher by 40 ° C.) than its melting point. .

The thermoplastic elastic resin heated to the above-mentioned temperature is discharged downward from the nozzle portion 16 and continuously drops linearly without interruption. If the melting temperature of the thermoplastic elastic resin at the time of discharge is set to a temperature higher by 30 ° C. to 50 ° C. than the melting point of the resin, a random three-dimensional loop is easily formed, and the contact portions between the loops are fused to each other. This is preferable because it can be kept in an easy state.

The nozzle portion 16 has a nozzle effective surface 1 having a predetermined width.
A large number of nozzles 16a having a hole diameter of about 0.5 mm are provided on the nozzle effective surface 18 at a predetermined hole pitch (for example, pitch: 5 mm). The extruder 15 discharges the thermoplastic elastic resin from the nozzle 16a such that the discharge amount per nozzle is 0.5 g to 1.5 g / min. The nozzle effective surface 18 is provided only in an area corresponding to the cross-sectional shape of the mesh cushion material 3 to be formed.
6a may be opened. Below the nozzle portion 16, a liquid surface 20a of a cooling liquid 20, such as water, which functions as a cooling means is located. This cooling liquid 20 is heated, for example, to a temperature of about 70 ° C.

A guide means 21 is provided below the nozzle portion 16. The guide means 21 includes the mesh cushion material 3.
A pair of endless belts 22 and 23 made of a metal net made of, for example, stainless steel and provided on upper and lower rollers 24 and 25 are provided so as to face both surfaces 3a and 3b in the thickness direction. The upper part of each belt 22 and 23 has a cooling liquid 20.
Is exposed on the liquid level 20a. These belts 22,
Reference numeral 23 denotes an endless running between rollers 24 and 25 by a driving mechanism using a motor or the like as a driving source.

The mesh cushion material 3 having a three-dimensional random loop network structure manufactured by the cushion material manufacturing apparatus 10 is cut into a desired shape by, for example, a cutting machine equipped with a heater wire. As the cutting means, besides using the heater wire, cutting by water jet, cutting by a press die, or cutting by a rotating disk-shaped blade (so-called vertical cutter) may be used. Alternatively, the mesh cushion material 3 may be formed into a desired shape under heat and pressure by hot pressing using a forming die.

Next, the steps of manufacturing the cushion body 1 will be described. The thermoplastic elastic resin material is supplied to the extruder 15 of the mesh cushion material manufacturing apparatus 10, the resin material is heated and softened, and the molten thermoplastic elastic resin material is supplied to the nozzle 1.
6a, the ink is spontaneously dropped between the belts 22 and 23. When the molten thermoplastic elastic resin falls between the belts 22 and 23, the continuous linear bodies 2 corresponding to the number of the nozzles 16a are formed, and are sandwiched and stopped between the belts 22 and 23. A random loop occurs while winding. Each of these continuous linear bodies 2 continuously loops in the direction indicated by the arrow A in FIG. 3 and forms a loop in a direction intersecting the direction A (for example, the direction indicated by the arrow B), while winding in a continuous manner.

By setting the pitch of the nozzles 16a so that the loops can contact each other, the loops are brought into contact with each other between the belts 22 and 23, and the contact portions between the loops are fused to form a net having a three-dimensional net-like structure. The cushion material 3 is obtained. By maintaining the temperature of the cooling liquid 20 at the annealing temperature of the continuous linear body 2 (pseudo crystallization accelerating temperature), the pseudo crystallization process can be performed simultaneously.

The mesh cushion material 3 with the loop fused is
The two sides 3a and 3b in the thickness direction are drawn into the coolant 20 while being regulated by the belts 22 and 23, and the coolant 2
At the same time as the hardening is performed within 0, the fused portion of each loop is fixed. The mesh-shaped cushion material 3 is formed by continuous lines 2 of a number corresponding to the number of the nozzles 16a being drawn in a random loop without interruption. The cushion material 3 is formed into a desired shape by cutting or hot pressing.

The clip 4 is attached to the frame line 4 by arranging the frame line 4 at a predetermined position on the back side of the mesh cushion material 3 and fitting the frame line 4 into the frame line attaching portion 5a of the clip 5. Then, the insertion portion 5c of the clip 5 is inserted into the mesh cushion material 3, and the retaining portion 5d is hooked on the continuous linear body 2 of the three-dimensional random loop, as schematically shown in FIG. By doing so, the frame line 4 is fixed to the mesh cushion material 3.

If the frame line 4 comes into contact with, for example, the cushion mounting surface of the vehicle body, and the generation of abnormal noise becomes a problem, the cover member 3 made of, for example, a polyester nonwoven fabric or the like is used.
0 may cover the frame 4. This cover member 30
Is bonded to the mesh cushion material 3 with an adhesive such as a polyester hot melt nonwoven fabric having a melting temperature of 150 ° C. The cover member 30 may be provided on the entire back surface of the mesh cushion material 3.

The reticulated cushion material 3 is formed by winding a continuous linear body 2 of 300 denier or more made of a thermoplastic elastic resin to form a large number of random three-dimensional loops, and the respective loops are brought into contact with each other in a molten state. Most of the contact portions are welded to each other to form a three-dimensional random loop and a three-dimensional network structure. Therefore, even if a large deformation is given by a large stress, when the entire cushion material 3 absorbs the stress while deforming three-dimensionally with each other, and the stress is released,
The cushion material 3 can be restored to the original shape by the rubber elasticity of the thermoplastic elastic resin. Moreover, since the continuous linear bodies 2 are fused to each other in a molten state, the cushion material 3 does not require a binder, and is made of a single thermoplastic resin, so that it can be easily recycled by re-melting.

When the cushion body 1 is recycled, an external force is applied to the frame 4 so that the frame 4 is meshed with the mesh cushion material 3.
And peel it off. In the case of this embodiment, the clip 5 is broken by applying a force of about 15 kgf, and the frame line 4 is formed within one minute after the disassembly operation is started.
Could be separated from

The mesh cushion material 3 from which the frame line 4 is separated is
For example, it can be cut into chips or made into fine powder and reused as a material recycled material. Since no resin is attached to the frame 4 separated from the mesh cushion material 3, the frame 4 can also be recycled as a metal resource.

FIG. 4 shows a cushion body 1 according to a second embodiment of the present invention. The cushion body 1 has a frame line insertion groove 40 formed on the back side of the mesh cushion material 3. The frame 4 is fixed by the clip 5 with the frame 4 inserted in the frame insertion groove 40. The other configuration is the same as that of the first embodiment, and the same reference numerals are given to the same parts as those of the first embodiment, and the description will be omitted.

The frame insertion groove 40 is formed by using a mold 41 as illustrated in FIG. The mold 41 has a frame line insertion groove 40.
And a built-in heater (not shown) can be heated to a temperature higher than the softening temperature of the continuous linear body 2 constituting the mesh cushion material 3. For example, by pressing a mold 41 heated to 230 ° C. at a position where the frame line 4 of the mesh-like cushion material 3 is provided, a frame line insertion groove 40 having a groove width of 9 mm is formed. A frame 4 having a wire diameter of 6 mm is inserted into the frame insertion groove 40, and the frame 4 is fixed by a clip 5 made of polyester resin. The frame line insertion groove 40 is such that the frame line 4 is
The depth is preferably set to be buried about 3 to 6 mm inside the surface of.

The frame 4 may be covered with a cover member 30 such as a polyester non-woven fabric to prevent generation of abnormal noise due to contact with the cushion mounting surface. The cover member 30 was adhered to, for example, the entire back surface of the mesh cushion material 3 by a polyester-based hot-melt nonwoven fabric adhesive having a melting temperature of 150 ° C.

When the cushion body 1 of this embodiment is recycled, an external force of about 15 kgf or more is applied to the frame line 4 to break the clip 5 and so on within one minute.
Was able to be separated from the mesh cushion material 3.

[Comparative Example] Using a general prescription of a soft and highly elastic urethane foam, a frame line having a wire diameter of 6 mm was set at a predetermined position of an upper mold of a mold whose temperature was previously adjusted to 50 ° C. The raw materials were prepared, the liquid temperature was adjusted to 25 ° C., and after mixing, the mixture was poured into a mold, foamed, and released after 10 minutes. Then, let the bubbles communicate by crushing,
A cushion body integrally formed with the frame line was obtained.

In order to recycle the cushion body of this comparative example, it is necessary to cut the cushion body with a knife along the frame line and then peel off the frame line from the cushion body. The peeling force required 30 kgf or more, and it took several tens minutes to separate all the frame lines. This was practically difficult to recycle because urethane foam was firmly attached to the frame line.

[0037]

According to the first aspect of the present invention, it is possible to recycle a cushion body having a three-dimensional random loop net-like cushioning material having good air permeability, excellent sag resistance and light weight, and a frame line. It will be easier. According to the second aspect of the invention, in addition to the effect of the first aspect, the frame line can be easily fixed to the net-like cushion material by the resin clip having a simple structure.

According to the third aspect of the present invention, since the frame line and the clip can be prevented from protruding outside the mesh cushion material, it is possible to prevent the frame line from interfering with the cushion mounting surface of the vehicle body or the like. it can. According to the invention described in claim 4, generation of abnormal noise due to contact between the frame line and the cushion mounting surface can be prevented.

According to the fifth aspect of the invention, it is possible to efficiently manufacture a lightweight cushion body having a three-dimensional random loop net-like structure cushioning material and a frame line and having excellent breathability and cushioning properties. The wire insertion groove can be easily formed, and the manufacturing cost can be reduced, for example, the processing steps are short and the number of working steps is small.

[Brief description of the drawings]

FIG. 1 is a sectional view of a cushion body showing a first embodiment of the present invention.

FIG. 2 is an exemplary front view showing an example of a clip used for the cushion body shown in FIG. 1;

FIG. 3 is a side view of an apparatus for manufacturing the mesh cushion material shown in FIG.

FIG. 4 is a sectional view of a cushion body according to a second embodiment of the present invention.

FIG. 5 is a sectional view showing a mold for forming a frame line insertion groove.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Cushion body 2 ... Continuous linear body 3 ... Reticulated cushion material 4 ... Frame line 5 ... Clip 5a ... Frame line attachment part 5c ... Insertion part 5d ... Retaining part 30 ... Cover member 40 ... Frame line insertion groove

Claims (5)

[Claims] A fineness of a thermoplastic resin of 300 to 100.
A net-shaped cushion material having a three-dimensional net structure having an apparent density of 0.005 to 0.2 g / cm ³ , in which a plurality of continuous linear bodies having a denier of 000 are wound in a loop shape and their contact portions are fused together. A frame line made of a metal or a synthetic resin to be attached to the mesh-like cushion material; a clip for fixing the frame line to the mesh-like cushion material; an insertion portion inserted into the mesh-like cushion material; and the continuous linear body. And a clip having a retaining portion which can be hooked on the cushion body. 2. The clip according to claim 1, wherein the clip includes a frame line attaching portion fitted to the frame line, an insertion portion including a pair of arms each having a width smaller than an outer diameter of the frame line and having a sharp tip. The cushion body according to claim 1, characterized in that the cushion body is a resin clip integrally having a retaining portion protruding outward from both sides of the insertion portion and facing the frame line mounting portion side. 3. The cushion body according to claim 1, wherein a frame line insertion groove for accommodating the frame line is formed in the net-shaped cushion material. 4. A cover member for covering the frame line is provided on the back side of the mesh cushion material.
The cushion body described. 5. A net having a three-dimensional net structure by discharging a softened thermoplastic resin from a plurality of nozzles, thereby winding a plurality of continuous linear bodies in a loop shape and fusing their contact portions with each other. Forming a cushion material; forming a frame line insertion groove by pressing a mold heated to a temperature higher than the softening temperature of the continuous linear body against the mesh-shaped cushion material; And a clip for fixing the frame line is inserted into the mesh cushion material, and the retaining portion formed on the clip is hooked on the continuous linear body to fix the frame line to the mesh cushion material. A method for manufacturing a cushion body, comprising: