JP2001314287A - Cushion body for seat in vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a comfortable cushion body for a seat in a vehicle capable of securing favorable feel of setting due to softness, achieving such excellent durability without generating buckling with relation to cushion performance as to capable of maintaining initial favorable feel of sitting for a long period, and achieving such excellent ventilation performance without generating steaming. SOLUTION: Inside a nonwoven fabric molded body 2, at least one layer of three-dimensional woven fabric 10 comprising surface side woven fabric and back side woven fabric apart from each other but connected to each other by connecting yarn comprising filament yarn, and provided with a specific thickness and a specific compression rate is provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion for a seat of a vehicle such as a railway vehicle and an automobile.

[0002]

2. Description of the Related Art As a cushion member for a seat of a vehicle such as a railway vehicle and an automobile, a cushion member made of an elastic urethane foam has been used in many cases. However, this urethane foam does not return sufficiently when compressed, sinks abruptly, shakes the body too much to provide stable sitting comfort, and has a sense of hardness. There is a problem that a good sitting feeling cannot be obtained. Furthermore, since the urethane foam has very little air or water vapor in its structure and very poor air permeability,
There was also a problem that the feeling of comfort was easily hindered.

[0003] Therefore, recently, a non-woven fabric obtained by partially fixing matrix fibers made of, for example, inelastic polyester-based crimped short fibers with binder fibers made of a synthetic resin having a melting point lower than the melting point of the short fibers. It has been proposed to use the molded body as a cushion body for a vehicle seat. According to this configuration, softness is imparted to the seating sensation, and the air permeability is also excellent.

[0004]

However, in the latter prior art, there is a problem in that the cushioning property is set in a relatively short period of time during repeated use, and the cushion becomes too soft, resulting in poor sitting comfort. That is, there was a problem that sufficient durability could not be obtained in the cushioning property. On the other hand, in the latter configuration, it is possible to cope by setting the compression repulsion force of the nonwoven fabric molded body to be high in advance in order to prevent the softness from becoming too soft even after repeated use. It has been difficult to ensure a good and comfortable sitting feeling. As described above, in the latter nonwoven fabric molded article, it is difficult to ensure both soft and good seating feeling and excellent durability in cushioning property.

The present invention has been made in view of such a technical background, and has sufficient softness to ensure a good seating feeling, and has no durable cushioning property and durability. An object of the present invention is to provide a cushioning member for a vehicle seat, which is capable of maintaining a good initial good seating feeling over a long period of time, and which is excellent in air permeability and does not cause unevenness. I do.

[0006]

Means for Solving the Problems In order to achieve the above object, the present inventors have made intensive studies and found that a front side knitted fabric and a back side knitted fabric which are separated from each other are placed inside a nonwoven fabric forming a cushion body. Has a structure in which at least one layer of a three-dimensional knitted woven fabric having a specific thickness and a specific compression ratio connected by a connecting yarn composed of a filament yarn is interposed, at least one layer is obtained. The present invention has been completed.

That is, the cushion member for a vehicle seat according to the present invention is a cushion member for a vehicle seat made of a nonwoven fabric, wherein the front side knitted fabric and the back side knitted fabric which are spaced apart from each other are filaments. 3 to 35 mm thickness, connected by a connecting yarn consisting of yarn, compression ratio 5 to 95
% Of a three-dimensional three-dimensional knitted fabric, at least in part of which, an inner body is interposed inside the non-woven fabric molding.

[0008] The thickness of the knitted fabric on both sides is 3 ~
By interposing a three-dimensional knitted fabric of 35 mm and a compression ratio of 5 to 95% inside, not only a good seating feeling with sufficient softness as a cushion body for a seat is imparted, but also cushioning properties In this case, sag due to use is effectively prevented, and excellent durability can be obtained. As described above, by interposing the three-dimensional knitted fabric according to the above configuration inside, it is possible to achieve both the provision of a soft sitting feeling and the cushion durability.
In addition, since both the nonwoven fabric molded article and the three-dimensional knitted woven fabric have a large number of voids through which air and water vapor can pass, the air permeability is also excellent.

[0009] The compression hardness of the outer skin layer of the seat portion in the nonwoven fabric molded product is preferably set in the range of 50 to 980 N, whereby the stability of the shape of the seat portion is improved and, consequently, good cushioning properties are exhibited. At the same time, the body pressure dispersibility becomes excellent.

[0010] The inner body may include a three-dimensional knitted fabric layer composed of one or more layers of the three-dimensional knitted fabric, and a compression hardness superimposed on at least one of upper and lower surfaces of the three-dimensional knitted fabric layer. It is preferable to have a nonwoven fabric layer of 50 to 780N. A relatively soft non-woven fabric layer having the above-described compression hardness is disposed adjacent to at least one of the upper and lower surfaces of the three-dimensional knitted fabric layer, so that when a body pressure is applied to the cushion body, a three-dimensional knitted fabric layer is formed. The space required for the expansion and contraction behavior of the knitted fabric will be sufficiently secured, and an environment will be formed in which the original behavior can be fully exhibited without impairing the flexibility of the expansion and contraction behavior of the three-dimensional knitted fabric. Therefore, a softer seating feeling can be imparted and cushion durability can be further improved. As long as the non-woven fabric layer has a compression hardness of 50 to 780 N, any of non-fused and non-fused points of entangled fibers may be used.

In particular, it is more preferable that the inner body has a structure in which the nonwoven fabric layer is overlapped on the upper and lower surfaces of the three-dimensional knitted fabric layer. Since the non-woven fabric layers having the above-mentioned compression hardness are arranged on the upper and lower surfaces of the three-dimensional knitted fabric layer, a softer seating feeling can be imparted and the cushion durability can be further improved. Further, the inner body is more preferably configured such that a nonwoven fabric layer having a compression hardness of 50 to 590 N is overlaid on the upper and lower surfaces of the three-dimensional knitted fabric layer.

[0012] It is preferable that the three-dimensional knitted fabric is disposed above the intermediate position in the overall thickness of the seat of the cushion body. By arranging the three-dimensional knitted fabric at such a position, it is possible to obtain a more excellent restoring force while maintaining an appropriate cushioning property.

The connecting yarn is preferably made of a filament yarn having a denier of 250 to 2,000 in that it can have a more excellent restoring force while maintaining an appropriate cushioning property.

When at least one of the upper and lower knitted fabrics of the three-dimensional knitted fabric has a perforated structure, the degree of freedom of the expansion / contraction behavior of the three-dimensional knitted fabric when a body pressure is applied is further improved. As a result, a softer seating feeling is ensured, and the air permeability is further improved.

The three-dimensional knitted fabric is preferably a three-dimensional knitted fabric. The three-dimensional knitted fabric has a greater degree of freedom in expansion and contraction behavior when a body pressure is applied than a three-dimensional fabric, and has excellent restoring force, so that a softer seating feeling is provided and cushion durability is further improved. Can be excellent.

The non-woven fabric molding is composed of inelastic polyester crimped short fibers, a thermoplastic elastomer having a melting point lower than the melting point of the short fibers by 40 ° C. or more, and an inelastic polyester. A nonwoven fabric formed of at least elastic composite fibers exposed on the fiber surface and formed by three-dimensionally intertwining these fibers. In the structure of the nonwoven fabric, the elastic composite fibers cross each other in a crossed state. A first flexible heat-fixed point formed by fusion, and a second flexible heat formed by thermal fusion of the elastic conjugate fiber in a state where the elastic conjugate fiber and the inelastic polyester crimp short fiber cross each other. It is desirable that the nonwoven fabric is formed integrally with the fixing points in a scattered manner.

In the structure, there are a first flexible heat fixing point, a second flexible heat fixing point and an elastic composite fiber connecting the heat fixing points, and these form a three-dimensional elastic structure, Since the short fibers are flexibly fixed by the elastic force, the compression recovery property and the compression durability are excellent, and furthermore, the cushioning of the cushion body is more effectively prevented from being set.

In this specification, "compression hardness"
Is a hardness (unit: N) measured by a test method specified in a hardness test of JIS K6401 5.4 (test piece thickness: 50 mm).

[0019]

1 and 2 show a cushion member for a vehicle seat according to an embodiment of the present invention. This cushion body (1) is a cushion body for a seat in a railway vehicle, and is an outer skin layer (2) made of a nonwoven fabric.
, An inner body (3) partially provided with a three-dimensional knitted fabric (10) is interposed.

The nonwoven fabric forming the outer skin layer (2) is a nonwoven fabric formed by three-dimensionally entangled fibers, and at least a part of the entangled points of the fibers is heat-sealed or the like. It is preferable to use a fixed one.

The upper surface of the outer skin layer (2), which forms the seat, has three edges except for the front side, which are formed as inclined surfaces that are gently inclined downward from the outside to the inside. The central portion surrounded by is a flat surface. Note that (2
The groove of 0) is a groove for inserting the drawing cloth in order to make the drawing cloth serving as the sheet skin conform to the flat surface of the central portion. The compression hardness of the seat outer layer (2a) forming the seat is preferably set in the range of 50 to 980N. If it is less than 50 N, the morphological stability of the seat portion is reduced, and the body pressure dispersibility is also deteriorated. On the other hand, 980
If it exceeds N, it is difficult to obtain a soft seating feeling, which is not preferable. It is preferable that the compression hardness of the outer skin layers other than the seat outer skin layer (2a) is set in the above range.

The thickness of the seat outer layer (2a) is not particularly limited, but is usually set in the range of 5 to 30 mm.

The inner body (3) comprises a three-dimensional knitted fabric layer (4) composed of one layer of three-dimensional knitted fabric (10), and a nonwoven fabric layer superposed on the upper and lower surfaces of the three-dimensional knitted fabric layer (4). (5) It has a three-layer structure consisting of (5).

As shown in FIG. 3, the three-dimensional three-dimensional knitted fabric (10) constituting the three-dimensional knitted fabric layer (4) has a plurality of through-holes (15) and (16) in a regular arrangement. The front side knitted fabric (11) and the back side knitted fabric (12) formed by the pore structure are arranged at a predetermined distance from each other in a spaced state, and the two knitted fabrics (11) and (12) are arranged between the two knitted fabrics. Thickness (t) connected by reciprocating connecting yarn (13) 3 to 35 m
m, a three-dimensional knitted fabric having a compression ratio of 5 to 95%.

The compression ratio is defined as that the three-dimensional three-dimensional knitted fabric is
The test piece was cut out into a test piece measuring 5 cm in width and 5 cm in width, and its initial thickness A was measured. Then, a weight of 5 kg was placed on the test piece, and the thickness B of the test piece after being left for 10 minutes was measured. Value.

Compression ratio (%) = (A−B) × 100 / A

In this embodiment, a knitted fabric structure is adopted as the front and back knitted fabrics (11) and (12). That is, the front side knitted fabric (11) is knitted in a knitting structure with hexagonal tortoise-shaped through holes formed by intersecting wale called an ordinal net or a mesh, while the back side knitted fabric (12) is similarly knitted in a mesh structure. Even if there is, it is knitted in a knitted structure with relatively small square through holes. Such a three-dimensional knitted fabric is knitted by a knitting machine having two rows of needle beds, most commonly a double Russell machine, but is not particularly limited to this. In addition, the same through-hole structure may be adopted as the front and back knitted fabrics (11) and (12).

As the front and back knitted fabrics (11) and (12), a woven structure may be employed. Examples of the woven structure include a plain woven fabric and a satin woven fabric.

According to the above construction, the front and back knitted fabric (11)
(12) connected with connecting thread (13) Thickness 3-35m
m, a three-dimensional knitted fabric (10) having a compression ratio of 5 to 95%,
By being interposed inside the outer skin layer (2) made of a nonwoven fabric molded article, a soft seating feeling is secured as the cushion body (1), and the cushioning property may be set even after long-term use. It is effectively prevented and has excellent durability.

Further, since the front and back knitted fabrics (11) and (12) have a perforated structure, the degree of freedom of the expansion and contraction behavior of the three-dimensional knitted fabric (10) when body pressure is applied can be improved. As a result, a softer seating feeling can be obtained. In addition, since it has a porous structure, the air permeability is further improved.

Furthermore, since the front and back knitted fabrics (11) and (12) employ a knitted fabric structure having a greater degree of freedom in expansion and contraction behavior upon application of body pressure than a woven structure, a softer seating feeling is ensured. can do.

When the thickness (t) of the three-dimensional three-dimensional knitted fabric (10) is less than 3 mm, it is difficult for the cushion body (1) to have a soft sitting feeling,
On the other hand, when the thickness (t) exceeds 35 mm, it tends to sink, and when used for a long time, it becomes easy to feel fatigue and the restoring force is reduced, so that the thickness (t) of the three-dimensional knitted fabric (10) is 3 to 3 mm. It needs to be 35 mm.

When the compression ratio of the three-dimensional knitted fabric (10) exceeds 95%, the cushion body (1) tends to sink and becomes prone to fatigue when used for a long period of time. Since it is difficult to provide a soft sitting feeling as (1), the compression ratio of the three-dimensional knitted fabric (10) needs to be set in a range of 5 to 95%. In particular, the compression ratio of the three-dimensional knitted fabric (10) is preferably set in the range of 20 to 80%.

The ground yarns constituting the front and back knitted fabrics (11) and (12) are multifilament yarns, spun yarns,
Monofilament yarns and the like, among which 250 to
2500 denier multifilament yarn or 250
It is preferred to use a spun yarn of ~ 2500 denier. If the denier is less than 250 denier, it is difficult for the three-dimensional knitted fabric (10) to have sufficient waist strength, and the hard connecting yarn (13) can be restrained sufficiently firmly by the front and back knitted fabrics (11) and (12). This is not preferred because the form stability is lowered. On the other hand, if it exceeds 2500 denier, the knitting and weaving work becomes difficult, and the cost is increased, which is not preferable.

As the connecting yarn (13) constituting the three-dimensional knitted fabric (10), it is necessary to use a filament yarn, and its thickness is preferably from 250 to 2,000 denier. When the thickness of the filament yarn is less than 250 denier, it is not preferable because it tends to sink when a body pressure is applied. On the other hand, when the thickness of the filament exceeds 2,000 denier, a feeling of hardness is felt and a sufficient soft seating feeling is obtained. It is not preferable because it becomes difficult to secure them. Incidentally, examples of the filament yarn include a monofilament yarn and a multifilament yarn.

The types of ground yarns constituting the front and back knitted fabrics (11) and (12) are not particularly limited. For example, synthetic fibers such as polypropylene, polyester, polyamide, polyacrylonitrile, rayon and the like, regenerated fibers, natural fibers such as wool, silk, cotton and the like can be mentioned. The material constituting the connecting yarn (13) is not particularly limited as long as it is a filament yarn. Further, for both the front and back knitted fabrics (11) and (12) and the connecting yarn (13), any of the above materials may be used alone, or some of them may be used in combination. Use of polyester is preferable because of excellent recyclability. In addition, both front and back knitted fabric (11)
The shape of the yarn constituting (12) and the connecting yarn (13) is not particularly limited, and may be, for example, a round cross-section yarn or a modified cross-section yarn.

Further, the structure of the connecting layer between the front and back knitted fabrics (11) and (12) constituted by the connecting yarn (13) is such that 10% or more of the connecting yarn is one or more than one stitch from the opposing stitch of the front and back knitted fabric. Preferably, the truss structure is shifted obliquely toward the wales and / or stitches separated by one or more courses. That is, the connecting yarn (13) is a front and back knitted fabric (11).
(12) A portion that reciprocates between the mutually opposing stitches at a right angle to both the knitted grounds may have a ratio of less than 90%,
One or more wales and / or
Alternatively, it is preferable to have 10% or more of a skewing portion that is obliquely shifted toward a stitch separated by one or more courses. With the structure of the connecting layer as described above, when the body pressure is applied, the uneven buckling due to the falling of the connecting yarn (13) is effectively prevented, and the cushioning property and the restoring force having almost no directivity are obtained. Can be retained. Among them, connecting yarn (1
It is more preferable that 30% or more of 3) has a truss structure which is obliquely shifted from the opposing stitches of the front and back knitted fabric to one or more wales and / or stitches separated by one or more courses.

The three-dimensional knitted fabric layer (4) may be composed of one layer of a three-dimensional knitted fabric (10), or may be formed by stacking two or more three-dimensional knitted fabrics (10). A combined configuration may be used. However, from the viewpoint of further improving the expansion / contraction behavior, the three-dimensional knitted fabric layer (4) is desirably composed of one layer of the three-dimensional knitted fabric (10).

The compression hardness of the nonwoven fabric layer (5) constituting the inner body (3) is preferably set in the range of 50 to 780N. If it is less than 50 N, it is not preferable because it tends to sink, whereas if it exceeds 780 N, the degree of freedom of the expansion and contraction behavior of the adjacent three-dimensional knitted fabric (10) at the time of applying body pressure is limited, and a soft good sitting feeling is obtained. It is not preferable because sufficient application cannot be performed. Among them, the compression hardness of the nonwoven fabric layer (5) constituting the inner body (3) is more preferably set in the range of 70 to 590N.

The constituent material of the non-woven fabric layer (5) is not particularly limited. For example, synthetic fibers such as polypropylene, polyester, polyamide, polyacrylonitrile and rayon, regenerated fibers, and natural fibers such as wool, silk and cotton And the like.

In the above embodiment, the inner body (3) has the nonwoven fabric layer (5) on both sides of the three-dimensional knitted fabric layer (4).
Although a configuration in which (5) is superimposed is employed, the configuration is not particularly limited to this configuration.
The nonwoven fabric layer (5) may be arranged so as to overlap the upper surface of the three-dimensional knitted fabric layer (4) as shown in (a), or the three-dimensional knitted fabric layer as shown in FIG. The nonwoven fabric layer (5) may be superposed on the lower surface of (4), or the three-dimensional knitted fabric layer (4) may be composed alone.

However, it is preferable that a nonwoven fabric layer (5) having a compression hardness of 50 to 780N is overlaid on at least one of the upper and lower surfaces of the three-dimensional knitted fabric layer (4). The relatively soft nonwoven fabric layer (5) having such a compression hardness is disposed adjacent to the three-dimensional knitted fabric layer (4), so that when the body pressure is applied to the cushion body (1), the tertiary knitted fabric layer (5) becomes tertiary. The space required for the expansion and contraction behavior of the original three-dimensional knitted fabric (10) is sufficiently ensured, and the original behavior of the three-dimensional knitted fabric (10) is not impaired. Therefore, a softer sitting feeling is provided and the cushion durability is further improved. Among them, the inner body (3) has a compression hardness of 50 on both upper and lower surfaces of the three-dimensional knitted fabric layer (4) as in the above embodiment.
More preferably, the nonwoven fabric layer (5) having a compression hardness of 50 to 590N is superposed on the upper and lower surfaces of the three-dimensional knitted fabric layer (4). Configuration.

In the present invention, the three-dimensional three-dimensional knitted fabric (1
It is desirable that the arrangement position of 0) is located above the intermediate position in the overall thickness of the seat of the cushion body (1). With such an arrangement, it is possible to further improve the restoring force while maintaining an appropriate cushioning property.

In the present invention, the nonwoven fabric forming the outer skin layer (2) is composed of an inelastic polyester crimped short fiber (34) and an elastic composite fiber (35), and these fibers are three-dimensionally entangled. It is more desirable to use a nonwoven fabric molded integrally in a state where the nonwoven fabric is formed.

The elastic conjugate fiber (35) is a thermoplastic elastomer (35a) having a melting point lower than that of the inelastic polyester-based crimped short fiber (34) by 40 ° C. or more.
And an inelastic polyester (35b), and the thermoplastic elastomer (35a) is exposed at least on the surface of the fiber (35).

Further, in the structure of the nonwoven fabric molding, a first flexible heat fixing point (40) formed by heat fusion of the elastic composite fibers (35) in a state where they cross each other, In the state where the conjugate fiber (35) and the inelastic polyester-based crimped short fiber (34) intersect, the second flexible heat fixing points (41) formed by heat fusion are scattered (see FIG. 5). ).

The flexible heat fixing points (40) and (41) are formed by heat fusion of the thermoplastic elastomer (35a). (4) When a load is applied to (41), the heat fixing point means a heat fixing point which can be freely deformed along the direction of the load and can be sufficiently recovered. The first flexible heat fixing point (40), the second flexible heat fixing point (41), and the elastic composite fiber (35) connecting the heat fixing points are present in the structure. Since the short fiber (35) is flexibly fixed by the elastic force by forming an elastic structure three-dimensionally, the heat fixing point does not break or deteriorate even when compressed from outside. It is excellent in recoverability and compression durability, and furthermore, it is possible to more effectively prevent the cushion body (1) from having sag in the cushioning property. Further, since the fibers are fixed at the flexible heat fixing points (40) and (41), the fibers do not fall off. The flexible heat fixing points (40) and (41) are preferably formed in an amoeboid shape. In this case, since the fixing force of the fixing points is further improved, the compression durability is improved. Better.

The inelastic polyester crimped short fibers (3
The fineness of 4) is preferably 2 to 200 denier. If the denier is less than 2 denier, it becomes difficult to realize a desired crimped form, which is not preferable. On the other hand, if it exceeds 200 denier, the number of the second flexible heat fixing points (41) to be formed is decreased, and the elasticity is lowered, which is not preferable. Among them, 5
More preferably, it is 100 denier.

The cut length of the inelastic polyester-based crimped short fibers (34) is preferably 20 to 150 mm. If it is less than 20 mm, the three-dimensional entanglement between the fibers becomes insufficient, and the elasticity is lowered, which is not preferable.
On the other hand, if it exceeds 150 mm, the directions of the fibers are too parallel to each other, which is not preferable. Especially, it is more preferable to set it to 35-100 mm.

The polyester is not particularly limited, and may be, for example, polyethylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, polybutylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, or a copolymer thereof. Polymers and the like can be mentioned.

In the elastic composite fiber (35), at least half of the fiber surface is a thermoplastic elastomer (35a).
Is desirably exposed. The composite ratio of the thermoplastic elastomer (35a) and the non-elastic polyester (35b) is preferably in the range of 30/70 to 70/30 by weight. As the composite form of the elastic composite fiber, for example, a side-by-side type, a sheath-core type and the like can be exemplified, and among them, a sheath-core type as shown in FIG. 6 is preferable.

As the thermoplastic elastomer (35a), one having a melting point lower than the melting point of the inelastic polyester-based crimped short fiber (34) by 40 ° C. or more is used. If the difference is less than 40 ° C., crimping of the inelastic polyester-based crimped short fibers (34) occurs when the thermoplastic elastomer (35a) is melted.

The material of the thermoplastic elastomer (35a) is not particularly limited, and examples thereof include a polyester elastomer. Above all, it is preferable to use a polyester elastomer. In this case, since the material is the same as the material constituting the short fiber (34), the adhesiveness between the thermoplastic elastomer (35a) and the inelastic polyester-based crimped short fiber (34) is used. Can be further improved, and the durability of the second flexible heat fixing point (41), which is the intersection with the short fiber (34), can be further improved, and the compression as the cushion body (1) can be achieved. Durability can be further improved, and sagging in cushioning properties can be more effectively prevented.

Among the above-mentioned polyester elastomers, it is preferable to use a polyether polyester from the viewpoint of further improving the adhesiveness to the inelastic polyester crimp short fibers (34). Further, a polybutylene terephthalate is used as a hard segment. A block copolymerized polyether polyester having polyoxybutylene glycol as a soft segment is more preferred.

On the other hand, examples of the inelastic polyester constituting the elastic composite fiber (35) include the same polyesters as those described above as the polyester constituting the inelastic polyester crimped short fiber. Butylene terephthalate is more preferred.

The nonwoven fabric molding as described above can be manufactured, for example, as follows. That is, the inelastic polyester crimped short fiber (34) and the elastic conjugate fiber (3
5) to form a web to form a web between the elastic composite fibers (35) and between the elastic composite fibers (3).
5) and the inelastic polyester-based crimped short fiber (34), a three-dimensional cross point is formed, and then the crimped short fiber (3) is formed.
4) and a thermoplastic elastomer (3
Heat-treating at a temperature 10 to 80 ° C. higher than the melting point of 5a),
It is manufactured by heat-sealing at least a part of these fiber crossing points. Note that the present invention is not particularly limited to this manufacturing method, and another manufacturing method may be used.

The thickness of the cushion body (1) of the present invention is usually 3 to 300 mm because the use of the cushion body (1) is a cushion body for a vehicle seat. Desirably, it is 200 mm.

The cushion member (1) for a vehicle seat according to the present invention is used not only as a cushion structure for a seating portion of a seat, but also as a cushion structure for a backrest portion of the seat. It is.

[0059]

Next, specific embodiments of the present invention will be described.

<Example 1> Polybutylene terephthalate was used as a hard segment (40% by weight), and polyoxybutylene glycol was used as a soft segment (60% by weight).
The block copolymerized polyether polyester elastomer was obtained by heating and reacting both. Then, this elastomer was spun into a sheath by a conventional method so that polybutylene-based terephthalate became a core to obtain an elastic composite fiber (sheath / core = 50/50 (weight ratio)).

Next, the elastic conjugate fiber and a hollow cross-section polyethylene terephthalate single fiber (12 denier, fiber length 6
4 mm, 9 crimps / inch) to obtain a web (for a skin layer).

A nonwoven fabric sheet (material: polyester) having a basis weight of 350 g / m ² was prepared.

On the other hand, a three-dimensional three-dimensional knitted fabric (29 cm long × 34 cm wide) was knitted according to the following specifications with the knitting structure shown in FIG.

Knitting machine: Double Russell knitting machine (9 gauge / inch, distance between kettles 15 mm) Wale density: 6 / inch Course density: 14 / inch Finished thickness (t): 13 mm Knitting yarn of surface knitted fabric: 1300 denier / 96f polyester / BCF multifilament (crimped yarn) Knitting yarn of back knit: 1300 denier / 96f polyester / BCF multifilament (crimped yarn) Connecting yarn: 800 denier polyester monofilament : 1 repeat 12 course turtle shell mesh (1 in 1 out) Plain knitting fabric: 1 repeat 12 course turtle shell mesh (1 in 1 out)

Using the constituent materials (web for outer skin layer, nonwoven fabric sheet, three-dimensional knitted fabric) obtained as described above, a cushion for a vehicle seat was manufactured as follows. That is, the above constituent materials are laminated in a forming mold,
The mold was placed in a hot blast stove and processed at a processing temperature of 200 ° C. and a processing time of 65 minutes.

Thus, a one-layer three-dimensional knitted fabric (thickness 13
mm, a compression ratio of 62.2%), a non-woven fabric layer having a compression hardness of 441 N (upper thickness 16 m)
m, the lower side having a thickness of 45 mm) was overlapped to obtain a cushion member for a seat in which the inner body was interposed in an outer skin layer formed of a nonwoven fabric. In addition, the thickness of the outer skin layer at the upper position of the inner body was 6 mm, and the thickness of the outer skin layer at the lower position of the inner body was 6 mm.

<Embodiment 2> As a three-dimensional knitted fabric, FIG.
Same as Example 1 except that a three-dimensional three-dimensional knitted fabric (29 cm long × 34 cm wide) knitted according to the following specifications with the knitting structure shown in Table 1 was used, and the thickness and compression hardness of both upper and lower nonwoven fabric layers were changed. Then, a non-woven fabric layer (thickness 16 mm) having a compression hardness of 441N is superposed on the upper surface of a three-dimensional knitted fabric layer composed of one layer of a three-dimensional knitted fabric (thickness 13 mm, compression ratio 54.7%). Compression hardness of 14 on the lower surface of the layer
An inner body formed by laminating a 7N nonwoven fabric layer (thickness: 45 mm) was obtained as a seat cushion member interposed inside an outer skin layer formed of a nonwoven fabric molded product.

Knitting condition of three-dimensional solid knitting machine Knitting machine: Double Russell knitting machine (9 gauge / inch, distance between pots: 15 mm) Wale density: 11 / inch Course density: 13 / inch Finished thickness (t): 13 mm Knitting yarn of surface knitting fabric: 1300 denier / 96f polyester / BCF multifilament (crimped yarn) Knitting yarn of back knitting fabric: 500 denier / 70f polyester
Multifilament Connecting yarn: 600 denier polyester / monofilament Surface knitted fabric structure: 1 repeat 2 course rhombus mesh (1
In / Out) Organization of the back knit: Double tricot (All in)

<Example 3> One layer of a three-dimensional three-dimensional knitted fabric (thickness 13 mm, compression ratio) was changed in the same manner as in Example 1 except that the design of the thickness and compression hardness of both upper and lower nonwoven fabric layers were changed. 6
Compression hardness 441 on the upper surface of the three-dimensional knitted fabric layer composed of 2.2%).
While the N nonwoven fabric layer (16 mm thick) is superimposed,
A cushion member for a seat is obtained in which an inner body formed by laminating a non-woven fabric layer (thickness: 45 mm) with a compression hardness of 147 N on the lower surface of the three-dimensional knitted fabric layer is interposed in an outer skin layer made of a non-woven fabric molded product.

Comparative Example 1 A seat cushion was obtained in the same manner as in Example 1 except that the three-dimensional knitted fabric was not used. That is, the compression hardness is 147N and the thickness is 74.
The inner body made of a non-woven fabric layer having a thickness of 2 mm was provided inside a skin layer made of a non-woven fabric molded product to obtain a cushion body for a seat.

Each cushion obtained as described above was evaluated according to the following test method. Table 1 shows the results.

[0072]

[Table 1]

<Evaluation of Softness> A person who was seated on each cushion body and had a feeling of pressure in the buttocks and thighs at the time of and after sitting was rated "x", and a person who felt a little feeling of pressure was evaluated. "△", those with almost no oppression were evaluated as "「 ", and those without any oppression were evaluated as" ◎ ".

<Cushion Set Test (Evaluation Method for Cushion Durability)> A set test is performed on each cushion in accordance with JIS S-1052, and the hardness of each cushion is maintained by the following formula. The rate (%) was calculated.

Hardness retention (%) = 100 × Y / X (X: initial compression hardness of cushion body, Y: compression hardness after set (durability) test)

As is evident from Table 1, the cushion members for seats of Examples 1 to 3 of the present invention have a sufficient softness and a good seating sensation, are excellent in compression durability, and have excellent initial durability. It was confirmed that the good seating feeling of can be maintained for a long period of time.

On the other hand, the cushion body of Comparative Example 1
The hardness retention is low and the cushion durability is inferior, and the good initial sitting feeling cannot be maintained for a long time.

[0078]

The cushioning material for a vehicle seat according to the present invention has a thickness of 3 to 35 mm in which both front and back knitted fabrics are connected with a connecting yarn composed of a monofilament yarn, and a compression ratio of 5 to 95.
% Of the three-dimensional knitted fabric is interposed in the non-woven fabric molded article, so that it can give a soft seating feeling as a cushion body for a seat, and the cushioning property is deteriorated even after long-term use. It is excellent in durability without generating and can maintain good initial sitting comfort for a long period of time. Furthermore, it is excellent in air permeability, and can be made comfortable without causing unevenness or the like.

When the compression hardness of the outer skin layer of the seat portion of the nonwoven fabric is set in the range of 50 to 980 N, the form stability can be improved and the body pressure dispersibility is excellent. It will be.

A three-dimensional knitted fabric layer is formed of one or more layers of a three-dimensional knitted fabric, and a compression hardness of 50 to 50 or more is superimposed on at least one of the upper and lower surfaces of the three-dimensional knitted fabric layer. In the case of including the 780N nonwoven fabric layer, a softer seating feeling can be imparted, the cushion durability can be further improved, and good initial sitting comfort can be maintained for a longer period.

When the inner body has a structure in which the nonwoven fabric layers are laminated on the upper and lower surfaces of the three-dimensional knitted fabric layer, a softer seating feeling can be imparted and the cushion durability can be further improved.

When the three-dimensional three-dimensional knitted fabric is interposed above the intermediate position in the overall thickness of the cushion body, the restoring force is further improved while maintaining an appropriate cushioning property. be able to.

When the connecting yarn is made of a filament yarn of 250 to 2,000 denier, the restoring force can be further improved while maintaining an appropriate cushioning property.

When at least one of the upper and lower knitted fabrics of the three-dimensional knitted fabric has a perforated structure, a softer seating feeling can be ensured and the air permeability can be further improved.

When the three-dimensional knitted fabric is a three-dimensional knitted fabric, a softer seating feeling can be imparted and cushion durability can be further improved.

The non-woven fabric molding is made of inelastic polyester crimped short fibers and the specific elastic conjugate fiber, these fibers are formed in three-dimensionally entangled form, and the first flexible heat-fixed point and (2) In the case of a nonwoven fabric formed integrally with the flexible heat fixation points in a scattered manner, it is possible to more effectively prevent the setting of the cushioning property from occurring,
Consequently, the good initial sitting comfort can be maintained for a longer period of time.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a cushion member for a vehicle seat according to an embodiment of the present invention.

FIG. 2 is a sectional view taken along line AA in FIG.

FIGS. 3A and 3B are views showing a three-dimensional knitted fabric, wherein FIG. 3A is a perspective view and FIG.

FIG. 4 is a sectional view showing a modification of the layer configuration of the cushion body.

FIG. 5 is an enlarged cross-sectional view showing an example of a fine structure of a nonwoven fabric molding.

FIG. 6 is a perspective view showing the elastic conjugate fiber with a part cut away.

FIG. 7 is a knitting structure diagram of a three-dimensional knitted fabric used in Examples 1 and 3.

FIG. 8 is a knitting structure diagram of a three-dimensional knitted fabric used in Example 2.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Cushion body for seats 2 ... Outer skin layer 3 ... Inner body 4 ... Three-dimensional knitted fabric layer 5 ... Non-woven fabric layer 10 ... Three-dimensional three-dimensional knitted fabric 11 ... Front side knitted fabric 12 ... Back knitted fabric 13 ... Connecting yarn 34 ... Inelastic Polyester crimped short fiber 35 Elastic composite fiber 35a Thermoplastic elastomer 35b Inelastic polyester 40 First flexible heat fixing point 41 Second flexible heat fixing point

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3B096 AD06 AD07 BA01 BA02 4L002 AA07 AB05 AC01 CB01 CB02 EA02 EA05 EA06 FA06 4L047 AA21 AA26 AB02 AB10 BB06 BB08 BC10 BC14 CA04 CA05 CA15 CC09

Claims (9)

[Claims] 1. A cushion body for a vehicle seat comprising a non-woven fabric formed body, wherein a front side knitted fabric and a back side knitted fabric which are spaced apart from each other are connected by a connecting yarn made of filament yarn, having a thickness of 3 to 3 mm.
An inner body having at least a part of one or more layers of a three-dimensional three-dimensional knitted woven fabric having a compression ratio of 5 to 95% of 5 mm is interposed in the nonwoven fabric body. Seat cushion body. 2. The cushion body for a vehicle seat according to claim 1, wherein the compression hardness of the outer skin layer of the seat portion in the nonwoven fabric molding is set in a range of 50 to 980 N. 3. A three-dimensional knitted woven fabric layer comprising one or more layers of the three-dimensional knitted woven fabric, wherein the inner body is overlaid on at least one of upper and lower surfaces of the three-dimensional knitted woven fabric layer. The cushion body for a vehicle seat according to claim 1 or 2, further comprising a nonwoven fabric layer having a hardness of 50 to 780N. 4. The cushion body for a vehicle seat according to claim 3, wherein the inner body has a structure in which the nonwoven fabric layer is overlapped on both upper and lower surfaces of the three-dimensional knitted fabric layer. 5. The vehicle according to claim 1, wherein the three-dimensional three-dimensional knitted fabric is interposed and disposed above an intermediate position in the overall thickness of the cushion seat. Seat cushion body. 6. The method according to claim 1, wherein the connecting yarn is a filament yarn having a denier of 250 to 2,000.
Item 10. A cushion body for a vehicle seat according to item 8. 7. The cushion body for a vehicle seat according to claim 1, wherein at least one of the upper and lower knitted fabrics of the three-dimensional knitted fabric has a through-hole structure. 8. The cushion body for a vehicle seat according to claim 1, wherein the three-dimensional knitted fabric is a three-dimensional knitted fabric. 9. The non-woven fabric formed article is composed of a non-elastic polyester crimped short fiber, a thermoplastic elastomer having a melting point lower than the melting point of the short fiber by 40 ° C. or more, and a non-elastic polyester,
And the thermoplastic elastomer is composed of elastic conjugate fibers at least exposed on the fiber surface, and these fibers are three-dimensionally entangled and formed into a nonwoven fabric, in which the elastic conjugate fibers cross each other. The first flexible heat-bonded point formed by heat fusion of the elastic composite fibers and the non-elastic polyester crimped short fibers are formed by heat fusion of the elastic composite fibers in a state where they cross each other. 9. A nonwoven fabric formed integrally with the second flexible heat fixing points in a scattered manner.
Item 10. A cushion body for a vehicle seat according to item 8.