JP2001095644A - Method for manufacturing body supporter for seat body of chair and body supporter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent an end face protruding in a needle shape from the cut end face of a cushion material with a solid network structure formed by bonding together many entangled loop shaped linear materials made of resin used for a body supporting member such as a seat body of a chair or the like at respective contact positions from breaking a cover material. SOLUTION: A cushion material 3 is cut into a substantially trapezoidal shape in section so that one wide face 3a of front and back wide surfaces is wider than the other wide face 3b. The edge parts 4a of a skin material 4 bonded to the wide face 3a by an adhesive agent are projected from the cushion material 3. The wide face 3b is bonded to the surface of an inner shell 2 by an adhesive agent 5. The peripheral cut face of the cushion material 3 is covered with the peripheral edge part of the wide face 3a o be deformed so as to come near to the peripheral edge of the inner shell 2. The edge 4a of the cover material 4 is fixed to the back surface side of the inner shell 2 by an rest adhesive agent 6.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method of manufacturing a body support constituting a body support device such as a chair or a bed, and to a body support.

[0002]

2. Description of the Related Art A seat and a backrest of a chair as an example of a body support device have a structure in which a cushion material is stretched on a plate-shaped inner shell. Conventionally, as a cushioning material used for a seat body or a backrest body of this chair, for example, as disclosed in Japanese Utility Model Publication No. 46-25135, a continuous porous soft sponge body is provided on the surface side of a hard core plate. And a foaming material such as urethane foam is arranged, a front sheet of the cushion material is covered with a surface sheet of thermoplastic soft synthetic resin over the entire periphery, and the periphery of the top sheet is positioned on the back side of the core plate. It is known that the periphery is heat-welded to the periphery of a back sheet made of another thermoplastic soft synthetic resin. However, such a foamed material has a drawback that it is easily stuffy due to poor air permeability.

Japanese Patent Laid-Open Publication No. Hei 8-61414 discloses a method in which a linear material winding in a random loop shape is formed of a thermoplastic resin, and a large number of such linear materials are entangled like cotton. By fusing the materials at the contact points, a cushion material having a three-dimensional net-like structure (cotton-like structure) is formed. Further, the cushion material is formed into a desired shape by a pair of molds that can be closely attached to and separated from each other. At the same time, it describes that a skin material such as a woven fabric is bonded to a cushion material.

As described above, this cushion material has a three-dimensional net-like structure, and therefore has an advantage that it has high air permeability and is hardly stuffy.

[0005]

However, the cushioning material has a width of 1 m, a length of 2 m and a thickness of about 3 m, for example.
Since it is provided in the form of a fixed board with a rectangular shape in plan view of about 7 cm to 7 cm, when it is cut into an area shape that matches the shape of the seat body and the backrest, the thickness of the cushion material that is the cut surface is The cut end portions of a large number of linear materials as materials protrude like needles. For this reason, when the wide surface and the four peripheral edges of the cushion material are covered with the skin material, the cut end of the linear material abuts on the inner surface of the skin material in the thickness portion of the cushion material, and the touch and the sense of contact with the body are reduced. There is a problem of being stiff, and in severe cases, there is a problem that the cut end of the linear material breaks through the skin material and projects outside.

In recent years, it is also important to incinerate a synthetic resin material without generating harmful substances such as nitrogen oxides and dioxins, and to mix it with smoke and dust due to environmental problems.

An object of the present invention is to solve these problems.

[0008]

In order to achieve the above object, a method of manufacturing a body support member such as a chair seat according to the present invention according to the first aspect of the present invention is a method of manufacturing a plurality of resin-made loop-shaped linear members entangled with each other. The cushion material having a three-dimensional net-like structure formed by fixing the materials at the contact points with each other is cut into a substantially trapezoidal side cross-section so that one wide surface is wide and the other wide surface is narrow. The edge of the skin material bonded to the wide surface on the wide side with the adhesive is protruded from the cushioning material, while the wide surface on the narrow side is abutted or bonded to the wide surface of the plate-shaped support. Then, the peripheral cut surface of the cushion material is covered with a peripheral portion of the wide surface on the wide side of the area and deformed so as to approach the peripheral edge of the plate-like support, and the edge of the skin material is covered with a plate. Fixing to the back side of the support It is an.

On the other hand, a method of manufacturing a body support member such as a chair seat according to the present invention according to the second aspect of the present invention comprises fixing a large number of resin-made loop-shaped linear members which are intertwined with each other at the contact positions. A skin material is adhered to one wide surface of the cushion material having a three-dimensional net-like structure by an adhesive, an edge of the skin material is protruded from the cushion material, and the other wide surface of the cushion material is widened by the plate-shaped support. Adhering to the surface, covering the surrounding cut surface of the cushion material with the peripheral edge of the wide surface on the side to which the skin material is adhered, and deforming it so as to approach the peripheral edge of the plate-like support, The edge portion is wound around and fixed to the back surface of the plate-shaped support.

[0010] The body support member such as the chair seat of the invention according to claim 3 is the body support member manufactured according to claim 1 or 2, wherein the cushion material is a polyester fiber. A three-dimensional net-like structure is formed by fixing resin-made loop-shaped linear members made of the following at the contact points with each other.

[0011]

Next, embodiments of the present invention will be described with reference to the drawings. 1 (a) to 1 (d) are schematic views showing a manufacturing process of the present invention, FIG. 2 is a plan view of an inner shell of a seat for a chair, FIG. 3 is a bottom view of the inner shell, and a seat in a chair. Is a front cross-sectional surface.

FIG. 1D is a schematic front sectional view of a seat body 1 manufactured by the manufacturing method of the present invention. The seat body 1 is an example of a plate-like support as shown in FIG. , A cushion material 3 adhered to the upper surface of the inner shell 2 with an adhesive, and a skin material 4 covering the cushion material 3. The end edge 4 a of the skin material 4 is adhered to the lower surface of the end edge of the inner shell 2. Therefore, the seat 1 can be directly incorporated into a chair.

The inner shell 2 is made of, for example, a synthetic resin such as polyester (a metal plate or a wooden plate may be used). The cushion material 3 is also made of polyester fiber or the like.
Consists of a continuous linear material (linear material) that is made by extruding a thermoplastic resin and randomly winding it. A large number of loop-like linear materials are entangled, and these linear materials are fused at the contact points. By doing so, the cushion material 3 has a three-dimensional net-like structure (cotton-like structure). Needless to say, the thickness of the linear material and the porosity of the three-dimensional net-like structure are set so as to be elastically deformed according to the weight of the person. The thickness of the linear material is not less than 300 denier and not more than 100,000 denier, and is preferably from 500 denier to 50,000 denier.

The skin material 4 is made of, for example, a fabric made of synthetic resin fiber such as polyester fiber, and has a function of improving the feel of a seated person. Next, a manufacturing process of the seat 1 will be described.

The cushion material 3 is provided as a raw material having a shape and dimensions of 1 m in width, 2 m in length, and approximately 3 cm in thickness.
Since it is a fixed board shape of a rectangular shape in a plan view of about 7 cm (refer to FIG. 1 (a) is a side cross section), first, roughly cut into a shape of the inner shell 2 in a plan view, (See FIG. 1 (b)). In this case, the cushion 3 is cut into a substantially trapezoidal side cross-section so that one wide surface 3a of the front and back wide surfaces is wide and the other wide surface 3b is narrow. Then, the skin material 4 is bonded to the wide surface 3a on the side having the large area by an adhesive. At this time, the peripheral edge portion 4a of the skin material 4 protrudes from the cushion material 3 (see FIG. 1B). As will be described later, the amount of protrusion is such that the periphery of the cushion material 3 is elastically deformed, then goes around the back surface side of the inner shell 2 and can be adhered at the back surface portion.

On the other hand, the wide surface 3b on the side of the cushion material 3 having a small area is abutted or adhered to the wide surface of the inner shell 2 as a plate-like support (see FIG. 1 (c)). In the case of bonding, as shown in FIG. 1 (b), the adhesive 5 is applied to a plurality of appropriate places on the surface of the inner shell 2 in advance.
Is preferably applied, but an adhesive (not shown) may be applied to a plurality of appropriate locations on one wide surface 3b of the cushion material 3.

Next, a peripheral cut surface of the cushion material 3 (a portion having a wedge-shaped cross section so as to become thinner as approaching the skin material 4) is covered with a peripheral portion of the wide surface 3a on the side having the larger area. The peripheral edge 4a of the skin material 4 is bent and deformed so as to approach the peripheral edge 2a of the shell 2, and the peripheral edge 4a of the skin material 4 is fixed to the back surface of the inner shell 2 with an adhesive 6 or the like (FIG. 1D). reference).

The cut end face of the linear material is projected laterally in a needle shape on the cut surface 3c of the cushion material 3. However, when the cut end surface is deformed so as to be rolled in as described above, the needle-shaped tip end is formed. When the peripheral edge 4a is wound around the back surface of the inner shell 2 so that the portion also curves downward and is wrapped by the wide surface 3a of the cushion material 3 adhered to the skin material 4, the needle-shaped tip Since the portion does not break through the skin material 4 and does not tingle, the sensation of the occupant when sitting (the sensation on the surface of the seat body 1) is improved.

In addition, the cushion material 3 together with the skin material 4 is used.
In the step of bending and deforming the peripheral portion of the inner shell 2 so as to approach the peripheral edge portion 2a of the inner shell 2, a mold (female mold) is used, and the skin material 4 is placed in a molding recess having an upward opening in the mold. The peripheral portion of the cushion material 3 is cut into the cut surface by pressing the inner shell 2 from above by pressing the narrow surface 3b of the cushion material 3 upward and pressing the inner shell 2 upward. It is preferable that the inner shell 3 is wound around the peripheral edge portion 2a of the inner shell 2 so that the inner surface 3c faces inward. At this time, the heated air or steam is
Is preferably blown in the direction of the cushion material 3 to promote the deformation of the cushion material 3 made of a thermoplastic resin. In the case of deforming by applying heat in this way, the adhesives 5, 6
Is to apply hot melt adhesive beforehand, or
It is preferable to interpose a hot melt adhesive sheet.
The hot-melt adhesive is once made mucous by heating, then hardened when cooled, and is given adhesive strength.

FIGS. 2 to 6 show a seat 1 to which the present invention can be applied.
Is shown in a more specific form. 2 is a plan view of the inner shell 2, FIG. 3 is a bottom view of the inner shell 2, and FIG.
5 is a right side view of the inner shell 2, FIG. 5 is a cross-sectional view of the seat 1 taken along line VV of FIG. 2, and FIG. 6 is a cross-sectional view of a chair to which the seat 1 is attached. In FIG. 6, reference numeral 10 denotes a pillar,
Reference numeral 11 denotes a seat support, reference numeral 12 denotes a metal base support, and reference numeral 13 denotes an intermediate support made of synthetic resin.

In this example, a plurality of ribs 14 are formed in the inner shell 2 in a rib shape so that the inner shell 2 is bent downward (elastic deformation) in accordance with the seating pressure. On the back surface of the inner shell 2, a rib 15 for reinforcement is formed. Reinforcing ribs 16 extending in the left-right direction are also formed on the lower surface of the front part of the inner shell 2. A plurality of engagement claws 17 projecting downward on both left and right sides of the back surface of the inner shell 2 are configured to fit into engagement holes 18 in the intermediate support 13.

FIGS. 7 (a) and 7 (b) show another embodiment of the manufacturing method of the present invention. In this embodiment, a large number of resin loop-shaped linear members entangled with each other are contacted with each other. Cushion material 3 having a three-dimensional net-like structure fixedly attached in
The skin material 4 is adhered to one of the wide surfaces by an adhesive (the hot melt adhesive or the like), and the edge 4a of the skin material 4
Is protruded from the outer peripheral edge of the cushion material 3, and the other wide surface of the cushion material 3 is bonded to the wide surface of the plate-like support 22 such as the inner shell 2 (FIG. 7A).
reference).

Next, the cut surface 3 around the cushion material 3
c is deformed by a jig 23 having a round bar shape or the like so as to be covered with the peripheral portion 4a of the wide surface near the side to which the skin material 4 is adhered and to approach the peripheral edge 22a of the plate-like support 22. While rolling the edge 4a of the skin material 4 on the back side of the plate-like support 22 (see FIG. 7B), then, the edge 4a
Is fixed to the back surface of the plate-like support 22 with an adhesive or the like. In the fixing method, when the plate-shaped support 22 is made of wood, a clamp such as driving and fixing with a U-shaped stapler or a nail may be executed.

FIG. 8 is a modification of the embodiment of FIG.
Without using the jig 23, the edge 4a of the skin material 4 is wound around the back surface of the plate-like support 22 while the peripheral cut surface 3c of the cushion material 3 is suddenly curved inward.
a is fixed to the back surface of the plate-like support 22 with an adhesive or the like. The present invention may be applied to a backrest body of a chair, and may be widely applied to a body support device such as a sofa or a bed.

[0025]

As described above, the method for manufacturing a body support member such as a chair seat according to the first aspect of the present invention provides a method for manufacturing a plurality of resin-made loop-shaped linear members entangled with each other. The cushion material having a three-dimensional net-like structure fixed at the contact point is cut into a substantially trapezoidal side cross-section so that one of the front and back wide surfaces is wide and the other wide surface is narrow. The edge of the skin material adhered to the wide surface on the wide side by an adhesive is protruded from the cushion material, and the wide surface on the narrow side is abutted or adhered to the wide surface of the plate-like support. The peripheral cut surface of the material is covered with the peripheral portion of the wide surface on the wide side of the area and deformed so as to approach the peripheral edge of the plate-like support, and the edge of the skin material is formed of the plate-like support. Characterized by being fixed to the back side .

Therefore, on the cut surface of the cushion material,
Although the cut end surface of the linear material is projected laterally in the shape of a needle, when deforming so as to involve as described above,
The wedge-shaped cross section of the cushion material on the side to which the skin material is adhered has a small resistance to bend and is extremely easily deformed. And the needle-shaped tip portion in the cut surface of the cushion material also easily bends downward,
If the peripheral edge of the skin material is wrapped around the back side of the plate-like support so that the portion is wrapped by the wide surface of the cushion material adhered to the skin material 4, the needle-like tip portion breaks through the skin material. Since no tingling occurs, the sensation of the occupant when sitting (the sensation of the surface of the seat or the like) is improved.

On the other hand, a method of manufacturing a body support member such as a chair seat according to the present invention according to the second aspect of the present invention comprises fixing a large number of resin-made loop-shaped linear members entangled with each other at the contact points. A skin material is adhered to one wide surface of the cushion material having a three-dimensional net-like structure by an adhesive, an edge of the skin material is protruded from the cushion material, and the other wide surface of the cushion material is widened by the plate-shaped support. Adhering to the surface, covering the surrounding cut surface of the cushion material with the peripheral edge of the wide surface on the side to which the skin material is adhered, and deforming it so as to approach the peripheral edge of the plate-like support, The edge portion is wound around and fixed to the back surface of the plate-shaped support.

According to such a manufacturing method, the cut end surface of the linear material protrudes laterally in a needle shape from the cut surface of the cushion material. The needle-like tip also curves downward,
If the peripheral edge is wrapped around the back side of the plate-like support so that the part is wrapped by the wide surface of the cushion material adhered to the skin material, the needle-like tip does not break through the skin material, Since the tingling does not occur, the feeling of the seated person when sitting (the feeling of the surface of the seat body) is improved.

The body support member such as the chair seat of the invention according to the third aspect is the body support member manufactured according to the first or second aspect, wherein the cushion material is a polyester fiber. Is a three-dimensional net-like structure in which resin-made loop-shaped linear members made of resin are fixed to each other at the points of contact with each other. Therefore, the material (synthetic resin) does not contain nitrogen or chlorine atoms, and thus is incinerated Occasionally, nitrogen oxides and dioxins are not generated, and the effect of easy recycling is exhibited.

[Brief description of the drawings]

1A is a diagram showing a first stage of a manufacturing process, and FIG.
FIG. 4 is a diagram showing a second stage of the manufacturing process, FIG. 4C is a diagram showing a third stage of the manufacturing process, and FIG. 4D is a diagram showing a fourth stage of the manufacturing process.

FIG. 2 is a plan view of the inner shell according to the first embodiment.

FIG. 3 is a bottom view of the inner shell.

FIG. 4 is a right side view of the inner shell.

FIG. 5 is a cross-sectional view of the chair seat taken along line VV of FIG. 2;

FIG. 6 is a front sectional view of the chair seat.

FIG. 7A is a cross-sectional view illustrating a first stage of a manufacturing process according to a second embodiment, and FIG. 7B is a cross-sectional view illustrating a first stage of a manufacturing process.

FIG. 8 is a cross-sectional view illustrating a manufacturing process according to a modification of the second embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Seat as an example of a body support member 2 Inner shell 3 Cushion material 4 Skin material 4a Edge 5,6 Adhesive

Claims (3)

[Claims] A cushion material having a three-dimensional net-like structure in which a large number of resin-made loop-shaped linear materials intertwined with each other are fixed at contact points with each other. The cross section is cut into a substantially trapezoidal shape so that the wide surface is narrowed, and the edge of the skin material adhered to the wide surface on the wide side with an adhesive is protruded from the cushion material, while the narrow side is Abuts or adheres to the wide surface of the plate-shaped support, and covers the peripheral cut surface of the cushion material with the periphery of the wide surface on the side of the large area, on the peripheral edge of the plate-shaped support. A method of manufacturing a body support such as a chair seat, wherein the body is deformed so as to be close to each other, and the edge of the skin material is fixed to the back side of the plate-shaped support. 2. A skin material is adhered to one wide surface of a cushion material having a three-dimensional net-like structure formed by fixing a large number of resin-made loop-shaped linear materials tangled with each other at contact points with each other, using an adhesive. The edge of the skin material is protruded from the cushion material, the other wide surface of the cushion material is adhered to the wide surface of the plate-like support, and the peripheral cut surface of the cushion material is widened on the side to which the skin material is adhered. A seat for a chair, wherein the edge portion of the skin material is wound around and fixed to the back surface side of the plate-like support while being deformed so as to be close to the peripheral edge of the plate-like support while being covered by the peripheral edge of the surface. A method for producing a body support such as a body. 3. The cushioning material according to claim 1, wherein the cushioning material is a three-dimensional net-like structure formed by fixing resin-made loop-shaped linear materials made of polyester fibers at mutually contacting points. A body support such as a chair seat manufactured by the manufacturing method described above.