JP2001190365A - Cushion pad and method for fabricating the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion pad wherein an unfamiliar sound, which is produced when a cushion material leaking out of a reinforcing material forming the rear side of a cushion pad makes contact with a metal frame forming a seat, can be avoided and further provide a method for fabricating the cushion pad by a simple process. SOLUTION: A reinforcing layer is formed integrally with the whole of the rear side of the cushion pad together with a cushion material. In the method for fabricating the cushion pad, a reinforcing layer forming material containing fibrous materials and a binder is applied to a cushion pad rear side forming surface of a predetermined die for forming the cushion pad, following which an expanding agent is injected into the die to expand the layer forming material, thereby making the expanded layer, being a cushion material, integral to the reinforcing layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a cushion pad and a method for manufacturing the cushion pad. More specifically, the cushion pad of the present invention is particularly useful for a cushion pad for a seat used in combination with a metal frame of a spring receiving type, and is used for vehicles, furniture, etc. for various automobiles, railway cars and the like.

[0002]

2. Description of the Related Art Conventionally, a cushion pad of a spring receiving type is provided on a back surface thereof for the purpose of improving sitting comfort, reinforcing a cushion material, and preventing noise caused by contact between the cushion material and a spring. Reinforcing materials such as cold sand, press felt, coarse felt (coarse blanket), and nonwoven fabric are integrated with the cushion material as a reinforcing layer. In order to integrate such a reinforcing layer with the foam material, first, the reinforcing material is die-cut and sewn so as to match the shape of the cushion pad back surface forming surface of a predetermined mold, and then a mounting hole is provided in the reinforcing material. After mounting the reinforcing material on the back surface forming surface of the predetermined mold so that the mounting hole and the reinforcing material mounting pin provided on the back surface forming surface of the predetermined mold match, a foam material is injected into the predetermined mold. It is a general method to make the foam.

However, in the above-described method, when the foamed material is foamed, the foamed material partially seeps out of the mounting hole provided in the reinforcing material and foams. , Only the cushion material (foam) appears. In addition, since the predetermined mold usually has unevenness rather than a flat surface, when the strong material is attached to the mold, the reinforcing material becomes wrinkled and a gap is generated, and a foam material partially seeps out from the gap. Even by foaming, a portion of only the cushion material appears on the back surface of the cushion pad. If the shape of the mold and the shape of the reinforcing material do not follow well, the foam material enters the gap between the mold and the reinforcing material, and the foamed cushion material leaks out to the edge of the reinforcing material on the back surface of the cushion pad.

As described above, when the cushion pad having only the cushion material on the back surface of the cushion pad is applied to a metal frame of a spring receiving type constituting a seat, the cushion material directly contacts the spring of the frame body. Therefore, even if the reinforcing material is integrated on the back surface of the cushion pad, the generation of abnormal noise due to the contact between the cushion material and the spring of the frame body cannot be completely eliminated.

[0005] In addition, it is very troublesome to perform die-cutting, sewing, and the like in accordance with the reinforcing material so as to conform to the shape of the cushion pad rear surface forming surface of a predetermined mold.

[0006] Japanese Patent Application Laid-Open No. 6-31062 discloses that
After laminating and placing the fiber assembly in a predetermined mold to be the back surface forming surface of the cushion pad, and further forming a shape corresponding to the back surface, heat treatment is performed to melt the fiber assembly, thereby forming a reinforcing layer on the back surface of the cushion pad. It has been proposed to form However, even with this method, the leakage of the cushion material that appears on the back surface of the cushion pad is not completely eliminated, and the manufacturing process is performed through a plurality of steps, which is very complicated.

[0007]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to eliminate abnormal noise caused by contact between a cushion material leaking from a reinforcing material forming a back surface of a cushion pad and a metal frame main body constituting a seat. It is to provide a cushion pad. Another object of the present invention is to provide a method for manufacturing the cushion pad by a simple operation.

[0008]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve the above-mentioned problems, and as a result, have found that the above-mentioned object can be achieved by using a cushion pad having the following structure. It was completed.

That is, the present invention relates to a cushion pad, wherein a reinforcing layer integrated with a cushion material is formed on the entire back surface of the cushion pad.

In the cushion pad of the present invention, since the entire back surface is covered with the reinforcing layer, even when the cushion pad is combined with the metal frame main body constituting the seat, the cushion material does not come into contact with the metal frame. Therefore, no abnormal noise is generated by the contact. Also, the reinforcing layer
Basic effects such as comfort and reinforcement of the pad are provided as in the conventional case.

Further, the present invention provides a method for forming a cushion pad, comprising: applying a reinforcing layer forming material containing a fibrous material and a binder to a cushion pad back surface forming surface of a predetermined mold for forming a cushion pad; The present invention relates to a method for manufacturing a cushion pad, wherein a foam material is injected and foamed to integrate a foam layer serving as a cushion material and a reinforcing layer.

According to this manufacturing method, the cushion pad can be easily realized, and noise generated by contact of the metal frame with a spring or the like can be eliminated. In the obtained cushion pad, since the entire back surface of the cushion pad is covered with the reinforcing layer forming material, there is no mounting error of the reinforcing material and the cushion material does not protrude from the gap between the mold and the reinforcing material.

In addition, according to this manufacturing method, since the reinforcing layer is formed by applying the reinforcing layer forming material, it is necessary to individually die-cut or sew the reinforcing material in accordance with the cushion pad back surface forming surface. Operation is easy without any. Also, there is no need to repeat design and trial production, and the time spent for development can be reduced. For example, conventionally, the shape of the reinforcing material was repeatedly produced by repeatedly designing and producing the shape according to the back surface of the cushion pad. However, according to the manufacturing method of the present invention, teaching on the production line according to the shape of the reinforcing material. Can be easily changed by appropriately changing.

In addition, since the reinforcing layer is formed by applying a reinforcing layer forming material, even a complicated portion having irregularities or the like, which is difficult to reproduce by die-cutting or the like, is easily and uniformly reinforced. Layers can be formed.

Further, since the reinforcing layer is formed by applying the reinforcing layer forming material, the mounting of the reinforcing material within a limited tact becomes unnecessary, and the working environment is improved.

The fibrous material used for the reinforcing layer forming material is preferably a chemical fiber and / or a natural fiber having a wire diameter of 2d or more. These fibrous materials are effective for forming a reinforcing layer such as sitting comfort and pad reinforcement.

The binder used for the reinforcing layer forming material is preferably a synthetic resin adhesive. These binders are quick-drying binders and have good productivity.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION A reinforcing layer forming material applied to a cushion pad rear surface forming surface of a predetermined mold contains a fibrous material and a binder. The fibrous material and the binder
Raw materials such as nonwoven fabrics conventionally used as reinforcing materials can be used.

As the fibrous material, rayon, polyester (polyethylene terephthalate), polypropylene,
Examples include synthetic fibers such as polyethylene, and natural materials such as cotton and palm wood.

The binder is not particularly limited. Examples of the synthetic resin adhesive include thermoplastic resins such as acrylic resins and polyvinyl acetate, and rubber binders such as natural rubber and styrene-butadiene rubber. Can be

These binders may be heat-sealed,
It may be a solution or an emulsion. Among these, a quick-drying binder using a fourth petroleum as a solvent is preferable. The amount of fibrous material and binder used is
The reinforcing layer can be appropriately adjusted at such a ratio as to be in the same state as the nonwoven fabric or the like.

The method for applying the reinforcing layer forming material to the cushion pad back surface forming surface of the predetermined mold is not particularly limited, and various methods can be adopted, but those capable of continuous injection such as an air gun or a spray gun are preferable. Using these methods, a reinforcing layer forming material is applied to an arbitrary portion by automatic control. By coating, a coating film serving as a reinforcing layer is formed on the back surface of the predetermined mold cushion pad.

The conditions for forming the coating film are not particularly limited, but it is preferable to perform the treatment at about 30 to 70 ° C. for about 30 to 300 seconds.

After applying the reinforcing layer forming material to the cushion pad back surface forming surface of a predetermined mold, a foaming material is injected into a predetermined mold and foamed, so that the foamed layer serving as the cushioning material and the reinforcing layer are formed. Molded integrally.

As the foam material, those used for various cushion pads can be appropriately selected and used according to a desired cushion material. As a foam material,
For example, there can be mentioned those which can be used as a compounding material for polyurethane foam. Specifically, polyether polyol,
Polymer polyols such as polyester polyols and polymer polyols, and organic polyisocyanates such as tolylene diisocyanate and diphenylmethane diisocyanate, and the like, further containing additives such as a foaming agent and a foam stabilizer.

The predetermined mold can be used according to the cushion pad. Normally, a combination of an upper mold and a lower mold is combined, and a foaming material is injected therein and foamed. The reinforcement layer is formed on either the upper mold or the lower mold, and this is used as the back surface forming surface of the cushion pad.

The foaming conditions are not particularly limited, and can be determined according to the type of various foaming materials.
About 7 to 10 minutes.

The cushion pad obtained by demolding after foaming has a reinforcing layer integrated with a cushion material to be a foamed layer on the entire back surface.

[0029]

EXAMPLES Hereinafter, the present invention will be described in detail with reference to examples, but the present invention is not limited to each example.

Example 1 Reinforcement layer forming material containing polypropylene (fibrous material) and acrylic resin (binder) (fourth petroleum solution)
Is applied to the upper mold (or lower mold) of a predetermined mold for molding the cushion pad by a spray gun, and then is applied.
After drying at 60 ° C. for 60 seconds, a reinforcing layer was formed on the upper mold (or lower mold). Next, a predetermined amount of a urethane foam compounding material (polymer polyol and tolylene diisocyanate) is injected into a lower mold (or an upper mold), and the lid is tightened.
After curing at 7 ° C. for 7 minutes, the mold was removed to prepare a cushion pad of the present invention in which a reinforcing layer was integrated on the back surface of the cushion pad.

COMPARATIVE EXAMPLE 1 A nonwoven fabric (Tafnel TST545, manufactured by Mitsui Petrochemical) was used as a reinforcing material and mounted on an upper (or lower) mounting pin to form a reinforcing layer. Next, a cushion pad was produced in the same manner as in Example 1.

The following evaluations were performed on the cushion pads for seats produced in the above Examples and Comparative Examples.

Generation of abnormal noise: Generation of abnormal noise was confirmed by an assembly test. Although the generation of abnormal noise was recognized in the comparative example,
No abnormal noise was generated in the example. In addition, the reproducibility of the product shape was good in the examples.

Claims (4)

[Claims] 1. A cushion pad wherein a reinforcing layer integrated with a cushion material is formed on the entire back surface of the cushion pad. 2. A foaming material is injected into the predetermined mold after applying a reinforcing layer forming material containing a fibrous material and a binder to a cushion pad back surface forming surface of a predetermined mold for molding the cushion pad. And producing a cushioning material by integrating the foaming layer and the reinforcing layer, which are to be cushion materials. 3. The method according to claim 2, wherein the fibrous material of the reinforcing layer forming material is a chemical fiber and / or a natural fiber having a wire diameter of 2d or more. 4. The method according to claim 2, wherein the binder of the reinforcing layer forming material is a synthetic resin adhesive.