JP2002000408A - Vehicle seat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicle seat excellent in durability, shape retainability and cushionability, hardly getting stuffy and rolling and easy for separating recycling. SOLUTION: The seat part has a cushion layer having a laminated structure obtained by laminating a nonwoven fabric formed by joining fibers each consisting of a thermoplastic resin and a three dimensionally reticulated structure body obtained by joining most of mutual contact parts of loops formed of filaments consisting of a thermoplastic resin. The seat face side of this cushion layer is made of a nonwoven fabric and two opposite faces in the thickness direction of the three dimensional reticulated structure body which constitutes this cushion structure have respectively their supports.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle seat which has excellent durability, shape retention and cushioning properties, is resistant to stuffiness and rolling, has a good ride comfort, and is easily separated and recycled. It is about.

[0002]

2. Description of the Related Art At present, as seats for vehicles mounted on trains and automobiles, those using foamed urethane or resin cotton or hard cotton to which crimped fibers are bonded are widely used as cushioning materials.

[0003] However, foamed-crosslinked urethane has extremely good durability as a cushioning material, but is inferior in moisture and water permeability and has heat storage properties, so that it is easily stuffed, and it is difficult to recycle because the material is not thermoplastic. In addition, even if it is incinerated, the incinerator is significantly damaged and the removal of toxic gas requires considerable labor and cost. In addition, such waste materials are sometimes discarded in landfills. However, it is difficult to stabilize the ground, so landfill sites are limited. Recently, it is difficult to secure landfill sites. Further, although the processability until processing into a final product is excellent, it is pointed out that there is a problem of pollution caused by chemicals used in the manufacturing process.

[0004] In order to solve the problem of humidity pointed out by such a cross-linked urethane-based material, for example, Japanese Patent No. 2580659 and Utility Model No. 259594 are disclosed.
No. 8, JP-A-10-108575, JP-A-10-108575
Japanese Patent Application Laid-Open No. 0-108758 proposes a method of blowing or blowing air from the surface of a seat to cool or warm the seat. However, these methods are effective as a one-time method, but they are often unwell if the forced air is constantly applied to the skin, which is unfavorable for health. Nor is it a solution to recycling or environmental issues.

On the other hand, JP-A-60-11352, JP-A-61-141388, and JP-A-61-1413
No. 91 discloses a technique using resin cotton in which polyester fibers are bonded with a rubber adhesive. Japanese Patent Application Laid-Open No. 61-137732 and the like have also proposed a device using a crosslinkable urethane. However, these cushioning materials are generally inferior in durability, are not thermoplastic and are not of a single composition, so that they are substantially difficult to recycle, have poor processability, and are used until the final product is obtained. Pollution problems caused by chemicals cannot be neglected.

Further, for example, JP-A-58-31150, JP-A-2-154050, and JP-A-3-220
Japanese Patent Application Publication No. 354/354 and the like also propose a cushioning material using polyester hard cotton, but a fragile amorphous polymer is used as an adhesive component of the heat bonding fiber (for example, Japanese Patent Application Laid-Open No. 58-136828). Gazette, JP-A-3-24921
Thus, the adhesive portion is fragile, and the adhesive portion is easily destroyed during use, resulting in a problem in durability, such as deterioration of the form and elasticity within a short period of time.

As a measure for solving such a problem, Japanese Patent Laid-Open Publication No.
Japanese Patent Application Laid-Open No. 245965 proposes a method of performing entanglement treatment. However, it is pointed out that the brittleness of the bonded portion is not solved, the elasticity is greatly reduced, and the processing is complicated. Japanese Utility Model Publication No. 2588857 also proposes a seat that attempts to achieve both cushioning and durability by changing the apparent density, but it is difficult to obtain satisfactory durability. Further, JP-A-63-158094 discloses that
A method has been proposed in which a silicone oil is applied to a base material made of hard cotton to reduce the friction coefficient of the fibers to increase durability and improve the texture, but there is a problem in the adhesiveness of the heat bonding fibers. Therefore, it is difficult to obtain satisfactory durability, and lacks suitability as a cushioning material.

For this reason, WO-91 is a cushioning material which uses a polyester elastomer which is flexible and recovers elasticity even after being deformed to some extent, and which uses a heat bonding fiber whose core component is made of inelastic polyester. / 19032, JP-A-5-156561, JP-A-5-16
No. 3654 has been proposed.

In these fiber structures, the content of polyalkylene glycol as a soft segment of the polyester elastomer used as an adhesive component is 30 to 50% by mass, and terephthalic acid as an acid component of the hard segment is 50 to 80% by mol. In addition, isophthalic acid is contained as another acid component, and as described in JP-B-60-1404, amorphousness is increased and the melting point is 1
At a temperature of 80 ° C. or lower, the melt viscosity is low, and the formation of the heat-bonded portion is facilitated to form a preferable amoeboid bonded portion. However, since plastic deformation is apt to occur and the core component is inelastic polyester, plastic deformation particularly under heating is remarkable, and the problem of insufficient heat resistance and compression resistance is pointed out.

Japanese Patent Application Laid-Open No. 11-42147 discloses that
There has been proposed a seat using an elastomeric heat-bonding fiber having more excellent durability and cushioning property than that using a non-elastomeric heat-bonding fiber and also having improved maintainability.
However, this improved technique has insufficient durability, and it is necessary to increase the density in order to increase the durability. However, increasing the density leads to a decrease in cushioning property and an increase in cost. As a remedy, Japanese Patent Application Laid-Open No. Hei 5-163654 proposes an elastic structure comprising only a heat-bonded conjugate fiber using a polyester elastomer containing isophthalic acid as a sheath component and an inelastic polyester as a core component. I have. However, in this technique, plastic deformation under heating becomes remarkable for the same reason as described above, so that heat resistance and compression resistance are reduced, and the suitability as a cushion material is impaired.

On the other hand, JP-A-6-299413 discloses that
Although a cushion structure using a heat-adhesive component that is unlikely to be plastically deformed has also been proposed, the setting of the base fiber cannot be avoided, and the problem of insufficient durability compared to urethane foam-based resin cannot be solved.

Furthermore, Japanese Patent Application Laid-Open No. 7-68061 proposes a three-dimensional net-like structure using only a thermoplastic elastic resin as a cushioning material having excellent heat resistance, cushioning property, air permeability and recyclability. I have. However, this net-like structure has a problem that the touch feeling is bad (a rough feeling is felt). Japanese Patent Application Laid-Open No. 7-238460 describes a measure for improving the tactile sensation.
JP, JP-A-7-238461, JP-A-7-238461
No. 38462 discloses a laminated structure in which a fibrous nonwoven fabric using a thermoplastic elastic resin as a heat bonding component and a three-dimensional network structure are joined and integrated. According to this remedy, although the effect of lamination is recognized, a complicated sorting step is required when recycling due to the integrated joining, which causes a problem in recyclability.

[0013]

SUMMARY OF THE INVENTION The present invention has been made in view of the various problems as described above, and its object is to provide excellent durability, form retention, and cushioning properties.
To provide a vehicle seat that is resistant to stuffiness, has a good body pressure distribution, and is not likely to cause rolling sickness, is stable and has a good ride quality, and is easy to separate and recycle. It is in.

[0014]

Means for Solving the Problems The present inventors have made intensive studies to achieve the above object, and as a result, as a constituent material of the seat portion, an upper layer made of a somewhat hard cushion material and a lower layer made of a soft cushion material. By constructing and limiting the excessive deflection of the soft cushion material to a certain range so that the laminated cushion material does not shift, the durability is remarkably improved, and it has a moderate cushioning property and good body pressure distribution Further, the present inventors have found that a vehicle seat which is hard to roll and has a very good ride comfort is obtained, and arrived at the present invention.

That is, the first configuration of the vehicle seat according to the present invention, in which the seat made of the thermoplastic elastomer resin forms a large number of loops, and the loops are entangled with each other, so that most of the contact portions of each other are formed. Has a cushion layer having a laminated structure of a three-dimensional network structure joined with a non-woven fabric to which fibers made of a thermoplastic resin are joined, and a seating surface side of the cushion layer is formed of a non-woven fabric to constitute the cushion layer The gist lies in that at least two opposing surfaces in the thickness direction of the three-dimensional network have supports.

In the present invention, it is preferable that the cushion layer of the laminated structure is wrapped and integrated with a cloth or a nonwoven fabric as defined in claim 2, and furthermore, as defined in claim 3, It is preferable that both the thermoplastic elastic resin and the nonwoven fabric of the cushion layer are made of a polyester resin.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, the thermoplastic elastic resin which is a constituent material of the three-dimensional network structure is a soft segment comprising a polyether glycol, a polyester glycol or a polycarbonate glycol having a molecular weight of 300 to 5,000. Polyester elastomers, polyamide elastomers, polyurethane elastomers, polyolefin elastomers, etc. obtained by block copolymerizing glycols, or olefin compounds in which long-chain hydrocarbon terminals have been changed to carboxylic acids or hydroxyl groups, and the like. By selecting and using a thermoplastic elastic resin,
Re-melting enables regeneration and recycling becomes easier.

Among the above, for example, as the polyester elastomer, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylene diol as a soft segment, or a polyester ester block having an aliphatic polyester as a soft segment is used. Copolymers are exemplified. More specific examples of the polyester ether block copolymer include terephthalic acid, isophthalic acid, naphthalene 2,
Aromatic dicarboxylic acids such as 6 dicarboxylic acid, naphthalene 2,7 dicarboxylic acid, diphenyl 4,4 ′ dicarboxylic acid;
An alicyclic dicarboxylic acid such as 1,4 cyclohexanedicarboxylic acid; an aliphatic dicarboxylic acid such as succinic acid, adipic acid and sebacic acid dimer acid; or at least one dicarboxylic acid selected from ester-forming derivatives thereof and the like. Aliphatic diols such as 1,1, butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol; 1,1 cyclohexanedimethanol;
An alicyclic diol such as 1,4 cyclohexanedimethanol; or at least one diol component selected from ester-forming derivatives thereof, and the like, and polyethylene glycol, polypropylene glycol, polytetraethylene having an average molecular weight of about 300 to 5,000. It is a ternary block copolymer composed of at least one kind of polyalkylene diol such as methylene glycol and glycol composed of ethylene oxide-propylene oxide copolymer. As polyester ester block copolymer,
The above dicarboxylic acid and diol and the average molecular weight of about 300
A triblock copolymer composed of at least one of each of polyester diols such as polylactones of 5,000 to 5,000 is exemplified.

In consideration of heat adhesion, hydrolysis resistance, stretchability, heat resistance, etc., terephthalic acid and / or naphthalene 2,6-dicarboxylic acid is used as the dicarboxylic acid, and 1,4-butanediol is used as the diol component. However, a ternary block copolymer of polytetramethylene glycol as the polyalkylene diol or a ternary block copolymer of polylactone as the polyester diol is particularly preferable. In a special case, a material into which a polysiloxane-based soft segment is introduced can be used. The thermoplastic elastomer resin of the present invention also includes blends of the above elastomers with non-elastomeric components, copolymers thereof, and polyolefin-based components having soft segments.

As the polyamide-based elastomer, nylon 6, nylon 66, and nylon 6 are used as hard segments.
10, nylon 612, nylon 11, nylon 12
And their copolymerized nylon as a skeleton and a soft segment having an average molecular weight of about 300 to 5,000.
Block copolymer composed of at least one kind of polyalkylene diol such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, glycol composed of ethylene oxide-propylene oxide copolymer, or a mixture of two or more kinds. You may. Furthermore, those obtained by blending or copolymerizing non-elastomeric components can also be used.

As the polyurethane elastomer, (A) a polyether having a hydroxyl group at the terminal having a number average molecular weight of 1,000 to 6,000 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.) And / or polyester and (B) a prepolymer in which both terminals are isocyanate groups reacted with a polyisocyanate having an organic diisocyanate as a main component,
(C) A polyurethane elastomer chain-extended by a polyamine containing a diamine as a main component can be exemplified as a typical example.

The polyesters and polyethers (A) include polybutylene adipate copolymerized polyesters having an average molecular weight of about 1,000 to 6,000, preferably 1,300 to 5,000, polyethylene glycol, polypropylene glycol, and the like. Polyalkylene diols such as polytetramethylene glycol and glycols composed of ethylene oxide-propylene oxide copolymers are preferable. As the polyisocyanate (B), a conventionally known polyisocyanate can be used, and diphenylmethane 4,4 ′ diisocyanate can be used. May be used, and a conventionally known triisocyanate may be added in a small amount, if necessary. As the polyamine (C), known diamines such as ethylenediamine and 1,2-propylenediamine are mainly used, and trace amounts of triamine and tetraamine may be used in combination as needed.

These polyurethane elastomers can be used alone or in combination of two or more if necessary. The melting point of the thermoplastic elastic resin is preferably 140 ° C. or higher, which can maintain heat resistance and durability, and is 160 ° C.
The use of the above is more preferable because the heat resistance and durability are improved.

The soft segment content of the thermoplastic elastic resin in the three-dimensional network structure constituting the seat of the present invention is desirably at least 5% by mass or more.
When the content is 5% by mass or less, the elasticity and durability are poor, so that it is not preferable. The preferred soft segment content is 15% by mass or more, more preferably 30% by mass or more. Further, from the viewpoint of heat resistance and sag resistance, the content is preferably 80% by mass or less, more preferably 70% by mass or less.

It is effective to add an antioxidant, a light stabilizer, a flame retardant, a coloring agent, an antibacterial agent, a fragrance and the like, if necessary, to impart functionality. Since the seat of the present invention is used for vehicles, it is preferable to apply flame retardancy to the cushion layer having a three-dimensional network structure. As a means for imparting flame retardancy, for example, phosphoric acid may be added during polycondensation. Known methods such as a method of copolymerizing the containing ester-forming compound or adding a nitrogen-containing component, and a method of adding a phosphorus-containing flame retardant or a nitrogen-containing component after polymerization can be employed.

The copolymerization ratio and the amount of addition may be appropriately set in consideration of the balance between the required degree of flame retardancy and mechanical properties such as rubber elasticity and hardness.

The thermoplastic elastic resin component in the three-dimensional network structure constituting the seat of the present invention preferably has an endothermic peak below the melting point in a melting curve measured by a differential scanning calorimeter. However, those having an endothermic peak below the melting point have significantly better heat and sag resistance than those having no endothermic peak. For example, as a preferable polyester-based thermoplastic resin used in the present invention, 90 mol% of terephthalic acid or naphthalene 2,6-dicarboxylic acid having rigidity in the acid component of the hard segment is used.
What contains, more preferably the content of terephthalic acid or naphthalene 2,6 dicarboxylic acid is 95 mol% or more,
Particularly preferably, after transesterification of the glycol component with 100 mol%, the polymerization is carried out to a required degree of polymerization, and then, as a polyalkylene diol, the average molecular weight is preferably 500 or more and 5,000 or less, particularly preferably 1,000 or less.
15 to 70% by mass, more preferably 30 to 70% by mass, more preferably 30 to 3,000 or less of polytetramethylene glycol.
When the copolymer is copolymerized at a ratio of not less than 60% by mass and not more than 60% by mass, if the content of terephthalic acid or naphthalene 2,6 dicarboxylic acid having rigidity in the acid component of the hard segment is large, the crystallinity of the hard segment is improved. Although it is difficult to deform plastically and the heat resistance is improved, the annealing resistance at a temperature lower than the melting point by at least 10 ° C. or more after the melting and heat bonding further improves the heat resistance and the compressive strain. Annealing from above further improves heat resistance and sag resistance.

The thus treated three-dimensional network structure more clearly shows an endothermic peak at a temperature from room temperature to a melting point in a melting curve measured by a differential scanning calorimeter. When annealing is not performed, an endothermic peak does not appear in the melting curve at room temperature or higher and at the melting point or lower. By analogy with this, it is considered that the hard segments are rearranged by annealing, forming pseudo-crystallization-like cross-linking points, and improving the heat resistance and sag resistance (this process is defined as pseudo-crystallization treatment). Do). This pseudo-crystallization effect is
It is also effective for polyamide-based elastic resins and polyurethane-based elastic resins.

The fibers made of the thermoplastic resin in the present invention are not particularly limited as long as they are fibers made of the above-mentioned thermoplastic elastic resin and / or thermoplastic inelastic resin. It is desirable to use a material made of thermoplastic inelastic resin as a fiber material, and specific examples thereof include polyester, polyamide,
Examples thereof include polyolefin. In the present invention, it is preferable to use one having a glass transition temperature of at least 40 ° C.

Examples of the polyester include polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PBT), Examples thereof include polybutylene naphthalate (PBN), polyarylate and the like, and copolyesters thereof.

Polyamides include polycaprolactam (NY6) and polyhexamethylene adipamide (NY6).
6), polyhexamethylene sebacamide (NY6-10)
Etc. can be exemplified. Examples of the polyolefin include polypropylene (PP) and polybutene-1 (PB-1).

As the thermoplastic inelastic resin used in the present invention, polyester is often used for the side material of the cushioning material. Therefore, when discarded, the side material and the nonwoven fabric can be recycled without being separated. Polyesters such as PET, PEN, PBN, and PCHDT, which also have good heat resistance, are particularly preferred. Further, PET, PEN, PBN, P
A flame-retardant polyester obtained by copolymerizing a phosphorus-containing ester-forming compound with CHDT or the like or containing a phosphorus-containing flame retardant (hereinafter, abbreviated as flame-retardant polyester) is preferable. Kaisho 51-823
No. 92, JP-A-55-7888, JP-B-55
No. 41610 and the like.
Although vinyl chloride has a self-extinguishing property, it is not preferable to use in the present invention because a large amount of toxic gas is generated when burned.

In the present invention, it is preferable to use a nonwoven fabric obtained by mixing and opening a low melting point heat bonding fiber and a base material fiber and then heat bonding as the nonwoven fabric because the shape of the seat cushion can be easily formed. The heat bonding component constituting the heat bonding fiber has a melting point of at least 100 ° C.
C is preferably low. More preferably, from the viewpoint of maintaining heat resistance and preventing thermal deterioration of the base material, the temperature is not less than 150 ° C.
C. or less is desirable. As a method for lowering the melting point of a thermoplastic resin, for example, in the case of polyester, copolymerization of isophthalate or the like which forms steric hindrance as an acid component, increase in the molecular weight of a glycol component, or melting point such as diethylene glycol Known methods such as a method of containing a substance having a lowering effect can be employed.

In the present invention, as described above, the seat portion is formed of a filament formed of a thermoplastic elastic resin to form a large number of loops,
A three-dimensional network structure in which most of the contact portions of each loop are intertwined and joined, and a cushion layer having a laminated structure of a nonwoven fabric in which fibers made of a thermoplastic resin are joined,
It is characterized in that the seating surface side of the cushion layer is made of a nonwoven fabric, and at least two opposing surfaces in the thickness direction of the three-dimensional network structure constituting the cushion layer have a support.

That is, the seat cushion layer of the seat of the present invention has a three-dimensional structure in which the upper layer is formed by mixing and opening the upper layer of a thermo-adhesive fiber made of a thermoplastic resin and a short fiber made of a thermoplastic inelastic resin. The contact part is made of a non-woven fabric bonded and integrated with a thermal adhesive component to provide body shape retention, seat shape retention and air permeability, and the lower layer is made of a number of thermoplastic elastic resins. The three-dimensional net-like structure in which the filament loops are fused to each other is provided with a vibration absorbing ability, heat-resistant set resistance and air permeability by a coil spring function using rubber elasticity.

Then, without joining the two laminated surfaces,
By providing a support on at least two opposing surfaces in the thickness direction of the three-dimensional network structure constituting the lower layer of the cushion, the nonwoven fabric cushion layer is prevented from being excessively bent, and the lower layer three-dimensional network structure is extremely bent. Compression and displacement between the upper and lower cushion layers are prevented. With such a configuration, the upper layer produces a hammock effect, and the lower layer does not deform more than a certain amount even when a biased load is applied, and does not shift laterally, so that rolling can be prevented, and the spring effect can be effectively prevented. It exerts extremely good ride comfort, improves the settling resistance of the entire cushion layer, and facilitates sorting and recycling.

That is, the seat cushion layer of the seat according to the present invention comprises a nonwoven fabric disposed on the upper layer and a three-dimensional network structure disposed on the lower layer, and at least two opposing surfaces in the thickness direction of the three-dimensional network structure. It has a support and is characterized in that the upper layer and the lower layer are not substantially joined, and the most preferred embodiment is the case where the upper layer and the lower layer are not joined.

The use of a nonwoven fabric which does not cause discomfort when sitting as the upper layer is disclosed in Japanese Patent Laid-Open Publication No. Hei 7-238462, and the effect of disposing a three-dimensional network structure as the lower layer is also disclosed. However, this publication discloses that the upper layer and the lower layer constituting the cushion layer have a characteristic that they are joined and integrated.

However, when a support is provided on at least two surfaces in the thickness direction of the three-dimensional network structure, and the upper layer and the lower layer are not joined on the laminated surface, the anti-shattering property is higher than when both layers are simply joined rigidly. Riding comfort is significantly improved. Although the reason is not clear, the amount of compressive deformation of the upper layer is the same as the amount of compressive deformation of the lower layer because the compressed upper layer does not deform more than a certain amount due to the support provided on at least two opposing surfaces in the thickness direction of the lower layer. In addition, the upper layer is deformed like a hammock due to the hanging effect of the opposing supports, and when the deformation load of the seated buttocks becomes a certain level or more, the lower layer is elastically pushed up by the effect of the elasticity and the spring, which is preferable. It is presumed to exhibit cushioning properties. In addition, the lower layer has a support in the thickness direction, and even if lateral displacement stress is applied, displacement and deformation are limited, so it is difficult for rolling to occur, and these produce good results and extremely good ride comfort. It is considered to be obtained.

By the way, if there is no support, it is not preferable because the deformation tends to be biased or displaced, so that rolling tends to occur. In addition, when the support of the lower layer is not installed facing the thickness direction, there is a case where a shift occurs to cause rolling. In a preferred embodiment of the present invention, the support preferably has a constant thickness. When the thickness of the support point at the contact portion with the upper layer of the support is 1 mm or less, the upper layer may be cut, which is not preferable. Conversely, if the thickness of the contact portion is 30 mm or more, it is not preferable because it gives an uncomfortable feeling. Preferably 5 mm or more, 20 mm or less,
More preferably, it is 8 mm or more and 15 mm or less. The thickness of the contact portion of the support may be formed by bending a metal plate, a wooden plate, a synthetic resin, or the like, and may be a pipe shape. It is also possible to use the thickness of the support itself.

If the height of the support is higher than the thickness of the lower layer, it is not preferable because it gives an uncomfortable feeling when sitting. Conversely, if the support is too low, rolling may occur. The preferred height of the support is at least １ ／ of the thickness of the lower layer and not more than the thickness of the lower layer when free, more preferably at least ／ of the thickness of the lower layer and not more than ／ of the thickness of the lower layer when free. It is. The support preferably forms a support surface in the width direction of 1/2 or more between two opposing surfaces, and most preferably supports the entire width. In a preferred embodiment of the present invention, the support supports the four surfaces in opposing directions. If the support and the lower bottom surface are joined, rolling can be completely prevented, and the seat can be further stabilized. Most preferable because it can be done. This effect further leads to an effect of maintaining a good body pressure distribution of the sitting buttocks. Note that the present invention includes a case where the outer periphery of the upper layer has a function of supporting without providing any special support.

On the other hand, the reduction of settling is achieved when the upper nonwoven fabric is harder and less deformable than the lower nonwoven fabric, and the three-dimensional network structure made of thermoplastic elastic resin is soft and easily deformed.
In the case where there is no support in the thickness direction of the lower layer, in the compression deformation behavior, the amount of deformation is determined by the hardness and strain amount of each cushion layer, and the deformation amount differs from the deformation amount when applying a constant strain individually. Show. In the case where the filament made of thermoplastic elastic resin has rubber elasticity, if the lower layer with less settling is greatly deformed and the upper layer with larger settling is limited to small deformation, the upper layer is higher than the set due to the constant strain of each layer alone. Gets better and the lower layers get worse.

When the laminated surfaces are joined, the compressive deformation stress is directly transmitted from the upper layer to the lower layer. If they are not joined, it is presumed that displacement occurs on the lamination surface, and that the deformation stress from the upper layer is transmitted to the lower layer in a biased manner. When the lower layer is supported in the thickness direction, the upper layer is deformed while being hung on the support, and does not deform more than a certain amount. The lower layer also undergoes the same deformation as that of the upper layer, and does not undergo unlimited deformation as in the case of no support.
Also, since the upper layer and the lower layer are not joined, the shear stress of the upper layer causes a shift within a range limited to the support on the lamination surface with the lower layer, and the deformation is transmitted to the lower layer, and the deformation stress is dispersed. It is presumed that it is deformed in a state where it is not. For this reason, it is considered that settling hardly occurs in both the upper layer and the lower layer.

When the upper layer and the lower layer are not joined, the seat is disassembled, and each component, for example, the side lands, the upper layer, and the lower layer can be easily separated and collected. In the case of joining, it is difficult to separate them individually without removing the joining surface, which is troublesome because it is troublesome.

The nonwoven fabric constituting the seat of the seat of the present invention is not particularly limited as long as it is made of a fiber made of a thermoplastic resin. This is preferable because it becomes easier. In particular, when a thermoplastic elastic resin is used as the heat bonding component of the heat bonding fiber, the cushioning property and the set resistance of the nonwoven fabric are further improved, which is a preferred embodiment. The most preferable soft segment amount when the heat bonding component is made of a thermoplastic elastic resin is such that the vibration absorbing function and the deformation stress absorbing function can be satisfied.
The content should be 0% by mass or more, but if it exceeds 70% by mass, the shape retention of short fibers is reduced, and the sinking becomes large.

The density of the non-woven fabric is not particularly limited, but is preferably in the range of 0.02 to 0.10 g / cc, which gives good touch and can provide a suitable elastic cushioning property. If the density is too low, the sinking becomes too large and it is difficult to provide a resilient cushioning property. If the density is too high, it becomes hard and the sitting comfort becomes poor, which is not preferable. The thickness of the non-woven fabric layer is not particularly limited, but care must be taken when the thickness is small, because the contact portion of the support may give a sense of incongruity as a touch. Preferably, it is 5 to 80 mm in which the surface layer function can be exhibited, and more preferably, it is in the range of 20 to 60 mm.

The fineness of the fibers constituting the nonwoven fabric is 22.2.
It is preferable that the fibers are composed of short fibers of not more than decitex (20 denier), and the fineness of the heat bonding fiber and the base fiber is 22.
When it exceeds 2 dtex, the apparent density of the nonwoven fabric can be given a preferable surface layer function of 0.02 g / cc or more,
When the content is 0.1 g / cc or less, the number of components may be reduced, and the touch as a dense structure may not be obtained and a comfortable touch may be impaired. Further, the thermal bonding fiber is preferable because the number of constituents decreases as the fineness increases, the thermal bonding points decrease, the dispersion of deformation stress deteriorates, the stress concentration at the bonding points increases, and the sag resistance decreases, which is preferable. It is good to set fineness. On the other hand, if the fineness is too small, the migration with the base fiber is deteriorated, and spots are generated at the heat bonding points formed by the heat bonding fibers, and the dispersion of deformation stress is deteriorated, and the stress dispersibility is unfavorably reduced. Preferred fineness of the heat bonding fiber is 1.1 to 11.1 dtex (1 to 10 denier),
More preferably, it is 3.3 to 6.7 decitex (3 to 6 denier). The matrix fiber is preferably 3.3 to 16.7 because it is necessary to maintain elasticity to give a proper sinking.
It is a decitex (3 to 15 deniers), more preferably 5.5 to 14.4 decitex (5 to 13 deniers).

The mixing ratio of the heat bonding fiber and the base fiber is 5/95.
If the mass ratio is less than 5/95, the number of joining points is reduced, and the finish of the shape formation is not preferable. Conversely, the mixing ratio is 60/40
Exceeding the mass ratio is not preferred because it is difficult to impart cushioning properties having an appropriate elasticity. When a thermoplastic elastic resin is used as the heat bonding component, the mixing ratio is 60/100.
Even if the ratio exceeds 40 mass ratio, a favorable cushioning property can be imparted, so that a large amount of heat bonding fibers may be used.

The three-dimensional structure is formed by mixing and opening, and then the majority of the contact portions are thermally bonded by thermoforming to fuse and integrate (preferably, all of the contact points are fused and integrated) to change the shape of the cushion material. Often given. During this molding, the lamination surface with the three-dimensional network structure is substantially flattened,
It is preferable that the lower three-dimensional network structure is also flat because it does not give a foreign-body sensation during sitting. In addition, the workability when assembling the seats by stacking them is improved, which is preferable.

The embodiment in which the concave portion for fitting is formed in the nonwoven fabric, and the three-dimensional network structure constituting the lower layer is fitted to the upper nonwoven fabric while supporting at least two opposing surfaces in the thickness direction of the three-dimensional network structure according to the present invention. Is particularly preferred. Then
The surface in contact with the frame has the lower part of the fitted three-dimensional net structure below the lower part of the nonwoven fabric, but the upper layer is suspended by the support, so it does not deform more than a certain amount, and the stress received is applied to the frame. This is a preferred embodiment because by imparting a transmitting function to the three-dimensional net-like structure, the cushion function can be more effectively exerted by appropriate deformation, and at the same time, the damage to the nonwoven fabric can be reduced. The preferred difference is at least 10 mm, more preferably at least 20 mm. If the thickness is less than 5 mm, it becomes difficult to effectively exert the function of the three-dimensional network structure against deformation, so it is desirable to avoid it.

On the other hand, the three-dimensional three-dimensional network structure has a three-dimensional spring structure in which continuous filaments made of a thermoplastic elastic resin form a large number of loops, and the loops are intertwined and joined and integrated at most of the contact portions. Since it is formed, it exerts a morphological and material cushion function. The three-dimensional spring structure and the rubber elasticity of the material receive the deformation stress given by the upper non-woven fabric, and the entire structure is deformed according to the deformation stress and the amount of deformation to absorb the stress and maintain the body shape with appropriate elasticity.
When the stress is released, the elasticity is immediately restored by the structural elasticity and the rubber elasticity, thereby exhibiting favorable cushioning properties and sag resistance. Vibration from the frame is also absorbed and attenuated by the vibration absorbing function of the thermoplastic elastic resin acting as a vibration blocking layer.

By the way, the three-dimensional net-like structure composed of the filaments made of only a known inelastic resin does not have rubber elasticity. Therefore, when it undergoes a large deformation that cannot be absorbed by the surface layer, it undergoes plastic deformation by compressive deformation. Come and stop recovering,
The flexure of the upper layer also increases, causing settling of both the upper and lower layers, resulting in poor durability. When the surface of the three-dimensional network structure is substantially flat, the deformation strain transmitted from the upper nonwoven fabric layer is transmitted between the surfaces, so that stress concentration hardly occurs. In the case where the upper layer is thin, if the laminated surface of the three-dimensional network structure is uneven, a foreign body sensation may be given to the buttocks when sitting, and in the present invention, the flattening is particularly preferable. It is a form.

If the filaments are not joined, the upper layer cannot be supported by rubber elasticity, and the upper layer will bend more, causing fatigue and deterioration of durability. Is not preferred because The preferable degree of the above-mentioned joining in the present invention is a state where most (preferably 50% or more) of the parts where the filaments forming the loop are in contact with each other, and particularly preferable is a state where all the contacting parts are joined. is there.

The fineness of the filaments constituting the three-dimensional network structure of the present invention is at least 111 dtex (100 denier).
111,111 decitex (100,000 denier) or less is preferable. The reason is that when the apparent density of the structure is reduced to 0.2 g / cc or less, the fineness is 11%.
If the number exceeds 1,111 decitex, the number of components decreases, and density unevenness occurs, resulting in a part with poor durability,
This is because fatigue due to stress concentration increases and durability is likely to deteriorate. On the other hand, if the fineness of the filament is too small, the compression resistance is reduced and the stress absorption performance due to deformation is reduced, so that 111 dtex or less is not preferable. The preferred range of the linear fineness is 333 decitex (300 denier) or more, in which the effect of the anti-compression property is easily exerted, and 55,555 decitex (50,000 denier) or less, which does not impair the denseness of the structural surface due to the decrease in the number of components. is there. More preferably, 1,111 dtex (1,000 denier)
As described above, it is 11,111 decitex (10,000 denier) or less.

The cross-sectional shape of the line forming the three-dimensional network structure is not particularly limited, but a hollow cross-section or a modified cross-section can provide a favorable anti-compression property (repulsive force) and touch, so that it is particularly preferable. preferable. The anti-compression property can be adjusted by the fineness and the modulus of the material used, and the gradient of the initial compressive stress can be adjusted by reducing the fineness or increasing the hollowness and irregularity of soft materials, and increasing the fineness slightly. In the case of a material having a rather high modulus, the hollow ratio and the degree of irregularity can be reduced to give a good anti-compressive property in sitting comfort. Another effect of having a hollow cross section or an irregular cross section is that by increasing the hollow ratio and the degree of irregularity, it is possible to further reduce the weight even when the same anti-compression property is imparted, and to promote energy saving. Can be

If the apparent density of the three-dimensional network structure is less than 0.005 g / cc, the resilience will be insufficient, and the vibration absorption capacity and deformation stress absorption capacity will be insufficient, making it difficult for the cushion function to be exhibited. Yes, conversely 0.25g /
If it exceeds cc, the resilience tends to be too high and the sitting comfort tends to be poor. Therefore, the apparent density of the three-dimensional network structure is
It is preferably 0.01 g / cc or more and 0.20 g / cc or less, more preferably 0.03 g / cc or more, in which sufficient vibration absorbing ability and deformation stress absorbing function are exhibited to easily secure the function as a cushion body. 0.08 g / cc or less.

The three-dimensional net-like structure may be selected as a preferred embodiment of a different fineness laminated structure which is optimally configured in combination with the apparent density of linear shapes having different fineness.

The preferred apparent density as a laminated structure of the three-dimensional network structure and the nonwoven fabric employed in the present invention is as follows:
It is in the range of 0.01 to 0.2 g / cc. 0.01 g /
If it is less than cc, cushion functions such as body shape retention and vibration absorption tend to be insufficient, while if it exceeds 0.2 g / cc, rebound resilience becomes too large and sitting comfort is unfavorably deteriorated. A more preferred range of the apparent density is 0.02.
0.1 g / cc, more preferably 0.03 to 0.08
g / cc.

The cushion layer constituting the seat portion of the vehicle seat according to the present invention is formed by laminating a nonwoven fabric on the seating surface side and a lower three-dimensional net-like structure, and preferably by laminating them without being joined and integrated. I have. However, if the three-dimensional net-like structure is merely inserted and laminated on the nonwoven fabric in a form having supports on at least two sides in the opposite thickness direction, the laminated form cannot be maintained when subjected to extremely large shear deformation. It can happen. Therefore, as a countermeasure, it is recommended as the most preferred embodiment in the present invention that the cushion layer having the laminated structure be largely wrapped and integrated with the side lining, the fabric, the nonwoven fabric, and the like to increase the retention of the laminated form. You. As the cloth or non-woven fabric to be used, a thin cloth having excellent breathability and high strength is preferable. For example, a cloth such as a metal cloth is used for a side lining such as a moquette or an inner layer.

The seat of the vehicle seat according to the present invention is preferably made of a three-dimensional net-like structure, if the cloth or non-woven fabric surrounding the side material and the cushion material, including the back portion, is entirely made of polyester, and the upper layer of the cushion layer is made of polyester. Is preferable because it is easier to regenerate as a polyester fiber only by separating the polyester fiber. It is most preferable to use the same material for the back material.

The method of regeneration is not particularly limited, and a known method, for example, a method of forming a non-woven fabric by card web formation by anti-hair treatment, a method of pulverizing and re-melting and re-pelletizing can be employed. If the three-dimensional network structure is also separated into only a single component, it can be re-pelletized and reproduced again as a three-dimensional network structure.
At this time, if other incompatible polyester is mixed, the shear rate when melt-molding the three-dimensional network structure is extremely slow, causing phase separation and abnormal flow,
Regeneration into a three-dimensional network structure becomes difficult. Therefore, in order to reproduce the three-dimensional net-like structure, it is necessary to separate the three-dimensional net-like structures so that other materials are not mixed.

However, if a melt-forming apparatus capable of forming at a high shearing rate such as injection molding is used, phase separation hardly occurs even if some different materials are mixed, so that melt-forming can be performed relatively easily. Therefore, in such a case, it is possible to regenerate to another product without separation as long as substantially all of the polyester resin is used.

In the present invention, if a three-dimensional net-like structure made of thermoplastic elastic resin is used also for the back of the seat, the back becomes less stuffy and the seat becomes more comfortable, so it is recommended as a particularly preferred embodiment. .

Next, a method of manufacturing the vehicle seat according to the present invention will be described. First, as a method of manufacturing a three-dimensional network structure used as a lower layer of the seat cushion layer, a thermoplastic elastic resin is distributed to each nozzle orifice by a multi-row nozzle having a plurality of orifices, and the melting point of the thermoplastic resin is set at 10 ° C or lower. At a melting temperature of about 50 ° C. higher, the nozzle is discharged downward from the nozzle, and is brought into contact with each other in a molten state to form a three-dimensional structure by fusing and joining, while being sandwiched by a take-off device and cooled by a cooling bath. A method of cooling and solidifying and then performing a heat treatment for pseudo-crystallization is employed.

For the spinning of the three-dimensional network structure, an ordinary multi-component extruder is used.
Melt spinning is performed at a temperature as high as about 0 ° C. 10 above the melting point
If the temperature is not higher than about ℃, melt fracture will occur and it will be difficult to form a normal filament. It is not preferable because the strips are less likely to fuse with each other and may form a net having insufficient adhesion. On the other hand, heating to a high temperature range exceeding 50 ° C. than the melting point is not preferred because thermal deterioration is remarkable and physical properties are deteriorated. From these viewpoints, the preferred melt spinning temperature is 15 to
The temperature is about 40 ° C. on the high temperature side, more preferably about 15 to 30 ° C. on the high temperature side.

If the residence time during melt spinning exceeds 30 minutes, thermal degradation is apt to proceed even when a preferable spinning temperature is employed, which is not preferred because physical properties may be deteriorated. Therefore, the residence time at the above-mentioned preferred melt spinning temperature is preferably about 15 minutes or less, more preferably 1 minute or less.
0 minutes or less.

The shape of the nozzle orifice used in manufacturing the three-dimensional network structure is not particularly limited, but may be a hollow cross section (for example, a triangular hollow, a round hollow, a hollow with a projection, etc.) and / or a modified cross section ( For example, a triangle, Y
(A shape with a high second moment of area such as a mold or a star)), it is difficult for the three-dimensional structure formed by the molten discharge filaments to relax the flow, and the flow time at the contact point is maintained longer This is particularly preferable because the bonding point can be strengthened.

As described in, for example, JP-A-1-2075, when heating is performed for bonding, the three-dimensional structure is easily relaxed to form a planar structure, and it is difficult to form a three-dimensional structure. Is not preferred. As the effect of improving the properties of the reticulated body, the apparent bulk is increased, the weight is reduced, and the anti-compression property is improved, the resilience is also improved, and it becomes difficult to set.

In the case of the hollow section, the hollow ratio is 80%.
If the ratio exceeds, the cross section is easily crushed. Therefore, it is preferable that the ratio is 10% or more and 70% or less, more preferably 20% or more and 60% or less, at which the effect of weight reduction is exhibited.
It is desired that the pitch between the holes of the orifice be a pitch that allows the loop formed by the filament to make sufficient contact. The pitch between holes may be shortened for a dense structure, and the pitch between holes may be increased for a rough structure.

The pitch between the holes of the nozzle for obtaining the three-dimensional network structure of the present invention is not particularly limited, but is preferably 3 to 20 mm, more preferably 5 to 10 mm. 3
If it is less than mm, the molten filaments will contact and fuse before forming the loop, making it difficult to form a normal network structure. Conversely, if the pitch between the holes exceeds 20 mm, adjacent filaments will contact each other during loop formation. It is not preferable because it is difficult to fuse. Since the loop diameter varies depending on the thickness of the filament and the discharge linear velocity, it is desirable to set an optimum pitch between the holes in balance with the filament to be formed.

Although the discharge amount is not particularly limited, it is desirable to set an optimum discharge amount for obtaining a desired wire diameter and a desired apparent density by a balance between the take-up speed and the linear speed of the filament. Densification and denier can also be performed as desired. For example, a different density layer can be formed by changing the pitch between rows or the pitch between holes, or by changing the pitch between both rows and between holes. Also, by changing the cross-sectional area of the orifice to give a pressure loss difference at the time of discharge, and utilizing the principle that the discharge amount of the molten thermoplastic resin extruded from the same nozzle at a constant pressure decreases as the orifice with a larger pressure loss, It is also possible to manufacture a three-dimensional network structure composed of filaments having different finenesses inside or between rows.

The molten thermoplastic resin is discharged downward from the nozzle, and is brought into contact with each other in a molten state while forming a loop to be fused to form a three-dimensional structure. At the same time as bending and deforming the meandering discharge line in the molten state of the surface to 45 ° or more to flatten the surface and bonding the contact points with the unbent discharge line to form a three-dimensional network structure, The three-dimensional three-dimensional network structure of the present invention is obtained by quenching and solidifying continuously with a cooling medium (usually, the cooling rate can be increased by using water at room temperature and the cost is reduced, which is preferable). .

The distance between the nozzle surface and the pickup point is at least 4
It is preferable to set the thickness to 0 mm or less to prevent the discharge filament from being cooled and the contact portion from being fused. The discharge amount of the discharge line is 5
In the case of g / min or more, the range is preferably 10 to 40 mm, and when the ejection amount of the ejection filament is less than 5 g / min, it is 5-2.
A range of 0 mm is preferred. The thickness of the net-like body is determined by the opening width of the take-off net sandwiching both surfaces of the three-dimensional structure in the molten state (the interval between the take-up nets). The width is 5m
m or more.

Then, after drying, drying is performed. At this time, if a surfactant or the like is added to the cooling medium, it should be noted that draining and drying may be difficult, and the thermoplastic elastic resin may swell. is there. The loop diameter and wire diameter can be arbitrarily adjusted according to the distance between the take-up conveyor and the nozzle surface installed on the cooling medium where the resin is solidified, the melt viscosity of the resin, the hole diameter and discharge amount of the orifice, etc. it can. By sandwiching and holding the discharge line in a molten state by a pair of take-up conveyors with adjustable intervals installed on the cooling medium, the parts that contact each other are continuously drawn into the cooling medium while being fused and solidified. When forming a network structure,
By adjusting the distance between the conveyors, the thickness can be adjusted while the fused network structure is in a molten state, and a desired thickness can be obtained.

At this time, if the conveyor speed is too high, the contact points may be insufficiently formed, or may be cooled until the fusion points are sufficiently formed, and the fusion of the contact portions may be insufficient. If the speed is too low, the melt stays too high and the density becomes too high. Therefore, it is necessary to adjust the conveyor speed so as to obtain an appropriate apparent density.

As a preferable method for carrying out the present invention, a temperature lower than the melting point of the thermoplastic elastic resin by at least 10 ° C. after the above-mentioned network structure is once cooled or at any time until the product is formed into a product by molding. And pseudo-crystallization by annealing. The pseudo-crystallization temperature is at least 10 ° C. lower than the melting point (Tm), and the α dispersion rise temperature (Tα) of Tanδ.
_cr ) It is desirable to perform the above. If you do this,
Heat resistance and sag resistance can be remarkably improved as compared with those having an endothermic peak below the melting point or not subjected to pseudo-crystallization treatment (no endothermic peak). The more preferable temperature of the pseudo crystallization treatment is (Tα _cr + 10 ° C.) to (T
m-20 ° C).

In the case where the three-dimensional network structure is once cooled and then manufactured through a drying step, pseudo-crystallization can be simultaneously promoted by setting the drying temperature to the annealing temperature. It is also possible to separately perform pseudo crystallization treatment in an arbitrary process until the formation. It is then cut to the desired length or shape and used as a lower layer of the cushion layer. As a preferred embodiment of the present invention, it is effective to use a similar material for the back.

The method of producing the nonwoven fabric used for the upper layer of the seat cushion of the vehicle seat according to the present invention is not particularly limited.
Although a known method can be applied, as a most preferred embodiment, a web in which a base material made of a thermoplastic adhesive resin having a thermal adhesive component of a thermoplastic elastic resin and a thermoplastic inelastic resin is mixed and opened is fitted to a cushion lower layer. A non-woven fabric is formed by filling a thermo-forming mold designed to fit therein and joining by thermo-forming. Hereinafter, this production method will be exemplified.

The fineness of the thermoplastic elastic resin is 22.2.
A heat-bonded fiber of decitex (20 denier) or less is obtained by melting a low-melting thermoplastic elastic resin and a high-melting thermoplastic elastic resin individually, spinning by known composite spinning, and then stretching to obtain a finished yarn. . However, in this method, since the melting point of the heat-adhesive component is low and it cannot be heat-set at a high temperature during stretching, only a high shrinkage ratio of 30% to 80% can be obtained. Is generated. Therefore, in order to solve such a problem, it is preferable to adopt a method in which a high-speed spinning of 3,000 m / min or more is adopted, and a shrinkage rate is reduced to 10% or less to make a finished yarn at a stretch. Next, crimping is applied and cut to a desired cut length to obtain a heat-bonded fiber.

The composite form of the heat-bonding fiber used in the present invention is not particularly limited. However, since the function as the heat-bonding fiber is required, the low-melting point component of the side-by-side type or the sheath-core type is 50% or more of the fiber surface. Preferably, the low melting point component occupies 100% or more of the fiber surface. The matrix fiber is made by imparting a latent crimping ability to the inelastic resin by a known asymmetric cooling method or a composite spinning method, and then performing heat treatment after drawing to develop a three-dimensional crimp, and then cutting or heat-treating after cutting to obtain a three-dimensional crimp. Obtained by expressing shrinkage.

Since the base fiber is required to have sag resistance and heat resistance, the initial tensile resistance value should be 30.9 centinewton / decitex (35 g / denier) or more, and 70 ° C.
It is preferable that the initial tensile resistance value at 8.8 cm / D or more (10 g / denier) or more.
From the viewpoint of bulkiness and compression resistance, the crimp degree of the three-dimensional crimp is 1
5% or more, and the number of crimps is preferably in the range of 10 to 25 pieces / inch. The thus obtained heat bonding fiber and base fiber are mixed and spread. If the amount of the heat bonding fiber is too small, the vibration absorbing function is undesirably reduced. If the amount of the heat-bonding fiber is too large, the bulkiness may decrease. Therefore, the mixing ratio of the heat-bonding fiber and the base fiber is preferably set to a range of 20/80 to 60/40 by mass ratio, and preliminary opening with an opener or the like. After being mixed, the fiber is opened with a card or the like to form a three-dimensional structure. The spread web is packed into a mold that can form a concave dent in the lower layer so that the lower three-dimensional network structure can be fitted, and then heat bonded. After heating to a temperature at least 10 ° C. higher than the temperature at which the fibers melt, compression and cooling are performed to obtain an upper layer made of a nonwoven fabric.

A preferred thermoforming temperature is a temperature 20 ° C. or higher than the flow start temperature of the heat bonding component. If the temperature is lower than 20 ° C., since the heat bonding component does not flow, it may not be possible to join at a contact portion between the fibers, which is not preferable. A more preferable heat treatment temperature is 50 ° C. or more and less than 80 ° C., which can shorten the heat treatment time. If the temperature is set to a high temperature of 100 ° C. or more, the thermal bonding component may be deteriorated by heat. The heating time is desirably in the range of 1 to 15 minutes. If the heating time is too long, the heat bonding component at the bonding point may not flow and a strong bonding point may not be formed. Is not preferred because it may cause thermal degradation.

As another method of forming the upper layer of the cushion material in the present invention, a method in which the spread web is packed in a forming die, compressed, and then heated can be adopted. In this case, it is preferable to use a mold having as small a heat capacity as possible because the time required for temperature rise can be reduced. For example, it is preferable to use a punching metal type mold because the heating / cooling medium can easily pass therethrough, and the temperature can be raised or cooled in a shorter time. Aluminum molds have a large heat capacity, so it takes a long time to raise the temperature and the workability and work efficiency may decrease.Therefore, open many holes for passing hot air and increase the rate of temperature rise through a high-pressure heat medium. It is preferable to pass a high-pressure cooling medium during cooling. As the heating and cooling medium, a gas that can be easily treated such as heated air or steam is preferable, and as the cooling medium, cooling air or the like is preferable.

If necessary, the metal fitting for the side ground can be buried in the upper layer during molding. When a metal fitting is not used, for example, a magic tape (registered trademark) or the like can be joined to the upper layer for joining. As the material of the magic tape used at this time, when the material of the upper layer is, for example, polyester, it is preferable to use the same type of polyester because it can be recycled without being separated.

Further, it is also possible to adopt a method in which a cut is made so that the side ground can be pulled in only at the upper layer cushion material portion, the side ground is drawn in, and the draw-in is joined and fixed at the bottom of the upper layer with a magic tape. Again,
It is preferable that the outer peripheral side of the side ground can be similarly joined to the bottom of the seat with a velcro. It is preferable to use the same material for the back.

Next, a support is formed to oppose the lower layer in the thickness direction. The material of the support is not particularly limited, but it is preferable to use a material that is durable and is not easily damaged or deformed during use. Examples thereof include metal, wood, synthetic resin, and composite products.

As an example, an example of a case where an injection molded article made of aluminum having a hollow or irregular cross section is used is shown below.
Using a hollow rectangular aluminum injection tube with a height of about / 5 and a contact portion with the upper layer of 12 mm in width, cut into a width that can cover the entire lower layer cushion surface in front of the seating surface and the back side of the seat, Using an aluminum plate of about 5 mm on the bottom surface, it is joined to the support by welding or bolts. Preferably 4
Install supports on all sides.

The lower layer is fitted into the support having the bottom joined,
Fit the lower layer put in the support to the upper layer that pulled the side ground,
The outer periphery of the side ground is pulled into the seat bottom and joined. Since the cushioning property also changes depending on the tension of the side ground, it is preferable to adjust the tension as desired.

Next, when set on a frame, the vehicle seat of the present invention is obtained. In another method, a cushion layer can be obtained by fitting and laminating an upper layer and a lower layer with a support attached thereto. When the obtained cushion layer is wrapped with, for example, a coarse metal band, for example, when using a velcro tape for retraction, the zipper of the upper layer is cut off so that the zipper of the upper layer functions to join with the side ground, or the tangled end of the velcro tape Should be projected. When using the drop fitting,
It may be wrapped in a gold cloth as it is.

Next, the seat is put on the frame after the side ground is covered and the seat is drawn in accordance with the shape of the seat, and the vehicle seat of the present invention is obtained. The material of the side lands to be used is not particularly limited, but if a material having good air permeability is used, it is difficult to get stuffy and is recommended as a preferred embodiment. Further, the use of a material having high hygroscopicity is a more preferred embodiment because the movement of water vapor from the hips when sitting is facilitated.

If the back material is made of a thermoplastic elastic resin or a non-woven fabric, it is possible to prevent stuffiness and to provide a suitable cushioning property and body shape retaining property. It is.

The vehicle seat of the present invention thus obtained is
A vehicle seat that has excellent durability, body shape retention and moderate cushioning properties, is resistant to stuffiness, does not roll easily, has good body pressure distribution, is extremely comfortable, and is easy to sort and recycle. Becomes

[0093]

EXAMPLES Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the following examples, and the present invention is not limited thereto. Modifications can be made and all of them are included in the technical scope of the present invention. The evaluation methods adopted in the examples are as follows.

[The melting point (Tm) and the endothermic peak below the melting point
H) The endothermic peak (melting peak) temperature was determined from an endothermic curve measured at a heating rate of 20 ° C./min using a TA50 / DSC50 differential thermal analyzer manufactured by Shimadzu Corporation.

[Apparent Density] A sample molded as a cushion layer was used as a sample, and the weight of the sample was shown as a value reduced by volume (average value of n = 4).

[Fineness of filaments] Each filament portion was cut out from 10 places of the sample, embedded in an acrylic resin, a cross-section was cut out, a slice was prepared, and a cross-section photograph was taken. Find the cross-sectional area (Si). In addition, the section obtained in the same manner was treated with acetone to dissolve the acrylic resin,
After defoaming in vacuo, the specific gravity (SGi) measured at 40 ° C. using a density gradient tube was determined, and then the striated 9, 9,
A weight of 000 m is obtained (unit: cgs). Fineness = [(1 / n) ΣSi × SGi] × 900,000

[Joining of the filaments] The joined fibers of the sample are pulled by hand, and it is judged by visual judgment that those which do not come off the joint are joined.

[Ride comfort] Maximum thickness 80 m formed by thermoforming polyester staple and polyester heat bonding fiber
m, the upper layer of the seat portion is composed of hard cotton formed at the center of the buttocks body with a minimum thickness of 45 mm, and a polyester moquette side with an air permeability of 80 cc / cm ² · second is drawn in the center of the upper layer,
The upper layer was fixed with Velcro on the bottom, and the lower layer was 8 mm thick on the bottom (the side was attached to the lower side with Velcro for pulling in), and the thickness 15 mm, the height 50 mm, the width on the front and back sides of the seat. A three-dimensional network structure (thickness: 65 mm) made of thermoplastic elastic resin filaments is inserted into a frame provided with a support of 250 mm, fitted into the upper layer with the side ground drawn in, and the whole is magically attached to the outer side ground. The seat was attached with tape. The back was made of a cushion molded of hard cotton, and the same backing as the seat was stuck to the back. The seat and back were set on a seat frame to prepare a seat, and a panelist was seated on a seat prepared in a room at 30 ° C. and 75% RH, and the following evaluation was performed. For the sake of comparison, the same structure without supporting the seat portion, the flame-retardant urethane 100
% And 100% of the nonwoven fabric were prepared and evaluated with the same shape of the cushion layer having no support or laminated structure (n = 5).

Evaluation 1 (Rolling Feeling): A seating load was applied to one side of the seating portion, and a seating load was applied to the opposite side, and the rolling state was qualitatively evaluated according to the following criteria. (No rolling feeling: ◎, almost no rolling feeling: ○, slightly rolling feeling: △,
Rolling feeling remarkable: ×).

Evaluation 2: The degree of the feeling of hitting the floor with "Don" when sitting was qualitatively evaluated sensory according to the following criteria (not felt; 、, almost felt; ○, slightly felt; △,
Feel; ×).

Evaluation 3 (feeling of stuffiness): Sit for two hours, and feel the stuffiness felt at the part in contact with the seat inside the buttocks and thighs,
It was qualitatively evaluated sensory according to the following criteria (almost no feeling: ◎,
Slightly stuffy; 、, slightly stuffy; Δ, markedly stuffy; ×).

Evaluation 4: A sensory evaluation was performed on the following criteria for how long the patient could sit on the seat within 8 hours (within 1 hour; ×, within 2 hours; Δ, within 4 hours; ○,
4 hours or more;）).

Evaluation 5: The degree of waist fatigue when sitting in a seat for 4 hours was qualitatively evaluated sensory according to the following criteria (no fatigue; 、, almost no fatigue; 、, slightly tired; △, extremely Tired; ×).

Overall evaluation: Out of the evaluations 1 to 5, ◎ was 4 points, ○ was 3 points, Δ was 2 points, and × was 1 point.
If the total score is 16 or more and does not contain △, it is “very good (（)”, if it is 16 or more, it does not contain ×, and “good (○)”. If it is 12 or more, it does not contain x. A sample containing “bad (△)” and × was evaluated as “bad (x)”.

Room-Temperature Durability of the Seat The same seat as that used for the evaluation of the riding comfort was prepared, and a 20 cm square weight (about 61 kg) was placed on the seat at an ambient temperature of 22 ° C. at a rate of 1 minute / time from 10 cm above the seat. After dropping and repeating this for 80,000 times, the rate of decrease in thickness and the rate of decrease in hardness were determined and evaluated according to the following criteria.

The thickness reduction rate was less than 5%: 4 points, less than 8%: 3 points, less than 10%: 2 points, and 10% or more: 1 point.
Less than 10% in hardness reduction: 4 points, Less than 15%: 3 points,
Less than 20%: 2 points, 20% or more: 1 point, and the total of evaluation points is 6 points or more: 、 ５, 5 points or more: 、 ４, 4 points or more: Δ,
A score of 4 or less was comprehensively evaluated as x.

Heat resistance and durability of the seat The same seat as that used for the evaluation of riding comfort was prepared, and a thickness (about 61 kg) of a 20 cm square weight was placed on the seat at an ambient temperature of 50 ° C. and left for 22 hours. Reduction rate (less than 10%: 、, less than 15%:
、, less than 20%: Δ, 20% or more: ×).

Example 1 Dimethyl terephthalate (DMT) or dimethyl naphthalate (DM
N) and 1,4 butanediol (1,4BD) were charged with a small amount of a catalyst, transesterified by a conventional method, polytetramethylene glycol (PTMG) was added, and polycondensation was carried out while increasing the temperature and reducing the pressure. An ether ester block copolymer elastomer is formed. Next, an antioxidant and a flame retardant are added, and the mixture is kneaded and kneaded, and then pelletized.
For 48 hours under vacuum to obtain a thermoplastic elastic resin. Table 1 shows the formulations of the raw materials.

[0109]

[Table 1]

Effective width: 1,000 mm, effective thickness: 80
An orifice having an outer diameter of 4 mm, an inner diameter of 3.2 mm and a hollow cross section of a triple bridge was formed on a nozzle surface having a width of 8 mm in the width direction and a pitch between rows of 6.9 mm.
Using a 2 mm equilateral triangle staggered nozzle, the thermoplastic elastic resin raw material (A-1) is discharged downward at a melt spinning temperature of 220 ° C. at a discharge rate of 3250 g / min. Distribute cooling water under 25cm, width:
A 1500 mm stainless steel endless net is arranged in parallel at 65 mm intervals so that a pair of take-up conveyors partially emerge above the water surface, and the discharge line in the molten state is meandered to form a loop while forming a loop. To form a three-dimensional network structure, and while sandwiching both surfaces of the three-dimensional network structure with a take-off conveyor, draw into the cooling water at 25 ° C. at a speed of 1 m per minute and solidify to flatten both surfaces. .
After that, it is cut into a predetermined size and heated with hot air of 110 ° C. for 15 minutes.
Pseudo crystallization was performed by heat-drying for minutes.

The obtained two-dimensionally flattened three-dimensional net-like structure (B1) has a hollow cross-section having a triangular diaper shape and a hollow ratio of 28% and a fineness of 6,222 decitex (5,600 denier). It is composed of filaments, most of which are joined, and the average apparent density is 0.05
g / cc, having an endothermic peak at 122 ° C. below the melting point,
The car passed the fuel test.

Separately, using a known composite spinning machine, the thermoplastic elastic resin A-3 is individually melted so as to become a sheath component and A-2 as a core component and distributed just before the orifice. 1.6 g / min hole (0.8 g / min: 0.8 g / min) per single hole so that the discharge rate is 50/50 mass ratio,
The yarn was spun at a spinning temperature of 245 ° C, spun at a spinning speed of 3,500 m / min, and the resulting fineness was 4.6 dtex (4.1 denier), and the shrinkage at 160 ° C dry heat: 8%. The material was converged, tow-shaped and mechanically crimped by a crimper, and cut into 64 mm to obtain a thermoadhesive fiber made of a thermoplastic elastic resin having a sheath-core section.

The matrix fiber has an intrinsic viscosity of 0.6 by a conventional method.
3 and 0.56 PET were distributed in a mass ratio of 50/50, and the spinning temperature was 285 ° C. at 3.0 g / min hole (1 g / min: 1 g / min) per single hole, so that the C-type orifice became side-by-side. Discharge, composite spinning at a spinning speed of 1,300 m / min, and then drawing at 70 ° C. and 180 ° C. in two steps, cutting the drawn yarn to 64 mm, and performing free heat treatment at 170 ° C. to develop a three-dimensional crimp Fineness: 6.7 dtex (6 denier), initial tensile resistance: 33.5 cm Newton / decitex (38 g / denier), degree of crimp: 20 %, A number of crimps: 18 fibers / inch were obtained.

The heat-bonded fiber and the matrix fiber thus obtained were mixed in a ratio of 40/6.
After mixing at 0 mass ratio and pre-opening with an opener,
The web obtained by fiber opening is set at a predetermined position on a female frame made of punching metal, which is used for a bucket-type seat and has a frame in which a three-dimensional net-like structure is fitted into a seating portion. The apparent density is 0.0
5 g / cc and packed with hot air at 180 ° C.
After heat treatment for 1 minute, the material was compressed with a male mold and immediately cooled, and then pseudo-crystallized at 105 ° C. for 10 minutes and cooled to obtain a cushion material upper layer (D1). The upper layer (D1)
114 ° C for thermoplastic elastic resin
Had an endothermic peak.

Next, as shown in the evaluation method of sitting comfort,
The seat and back were created and set on the seat frame to obtain the seat. Table 2 shows the characteristics of the obtained cushion layer and the evaluation results of the seat. As is clear from Table 2, the seat of Example 1 was excellent in normal temperature durability, heat resistance durability and sitting comfort.

[0116]

[Table 2]

Example 2 40 mol% of dimethyl isophthalate (DMI) and DMT
60 mol% and ethylene glycol (EG) were charged together with a small amount of a catalyst, transesterified and polymerized by a conventional method to obtain a polyester resin having a melting point of 112 ° C. Using this polyester resin as a sheath component, using a PET having an intrinsic viscosity of 0.63 as a core component, and using a heat-bonded fiber obtained in the same manner as in Example 1 except that the spinning temperature was changed to 285 ° C. The same material as that used in Example 1 was mixed with 30% by mass and 70% by mass and opened to prepare a web, and a cushion material upper layer (D2) similar to that in Example 1 was obtained. Table 2 shows the evaluation results of the seat obtained in the same manner as in Example 1 by using the same lower layer (B1), support and bottom surface as in Example 1. As is evident from Table 2, even if the thermoplastic non-elastic resin is used as the thermal adhesive component of the nonwoven fabric, those which fall within the scope of the present invention have excellent room temperature durability, heat resistance durability and sitting comfort. Was.

Example 3 Using a thermoplastic elastic resin (A-3), a spinning temperature of 20
The lower layer three-dimensional network structure (B3) obtained in the same manner as in Example 1 except that the temperature was changed to 0 ° C., the cross section of the filament was a triangular tapered hollow cross section, and the hollow ratio was 25%, and the fineness was fine. : 6,
Most of the 555 decitex (5,900 denier) filaments are joined to flatten both sides, and the apparent density is 0.0
At 5 g / cc, it passed the vehicle fuel test.

The apparent density of the upper layer was 0.35 g / surface layer.
cc, central part: 0.50 g / cc, bottom part: 0.60 g
/ Cc, using the upper layer (D2) obtained in the same manner as in Example 2 except that the upper layer was formed so as to be / cc and the three-dimensional network structure for lower layer (B3). Table 2 shows the evaluation results of the obtained vehicle seats. As is evident from Table 2, even when the upper layer touch is softer than the lower layer, those which fall within the scope of the present invention exhibited good room temperature durability, heat resistance durability and sitting comfort.

Comparative Example 1 The same procedure as in Example 1 was carried out except that the same support as in Example 1 was provided on only one surface on the rear side of the seating portion as the lower layer (B1).
Table 2 shows the seat evaluation results created in the same manner as described above. Table 2
As is clear from the above, this comparative example was out of the range of the present invention, and although it had good room-temperature durability and heat-resistant durability, it had a problem in rolling properties and was slightly inferior in sitting comfort.

Comparative Example 2 Table 2 shows the seat evaluation results prepared in the same manner as in Example 2 except that the support was not provided. This comparative example is also out of the range of the present invention and has good room-temperature durability and heat-resistant durability, but has a problem in rolling properties and is inferior in sitting comfort.

Comparative Example 3 A 100% nonwoven cushion layer manufactured in the same manner as the upper layer of Example 2 by using the same opened web as in Example 2 and using a mold having the same cushion layer as the whole. Table 2 shows the evaluation results of the vehicle seats created by using the above. This comparative example, which does not satisfy the requirements of the present invention and is composed of a cushion layer made of 100% nonwoven fabric, is inferior in normal temperature durability, heat resistance durability and sitting comfort.

Comparative Example 4 Thickness that passes the vehicle flame retardancy standard (vehicle fuel test): 40 m
Table 2 shows the evaluation results of seats obtained by cutting, slicing and bonding urethane foam having an m, apparent density: 0.05 g / cc and forming the same shape as the cushion layer of Comparative Example 3.
Since this comparative example uses urethane foam that deviates from the requirements of the present invention, it has excellent room temperature durability and heat resistance durability,
Uncomfortable sitting.

Comparative Example 5 The three-dimensional network structure for the lower layer of the cushion layer obtained in the same manner as in Example 3 except that the spinning temperature was 175 ° C. and the pseudo-crystallization treatment was not performed, the shape was stopped. Most of the filaments were not joined. Using this lower layer (B4), the evaluation results of the seat obtained in the same manner as in Example 2 show that when the lines of the three-dimensional net structure deviating from the present invention are insufficiently joined, the riding comfort is reduced by rolling. Feeling: ◎, Feeling with floor: △, Fatigue: 蒸, stuffiness: 、, Seating time: △, Overall: △
The ride was somewhat inferior. In terms of durability, the room temperature durability was 2 for hardness reduction, 2 for thickness reduction, overall: Δ, and Δ for heat resistance, which were inferior in room temperature durability, heat resistance durability, and sitting comfort.

[0125]

According to the present invention, a three-dimensional net-like structure is provided in which the seat is formed of a loop made of a thermoplastic elastic resin to form a loop and most of the contact portions are joined to each other. And a cushion layer having a laminated structure of a non-woven fabric in which fibers made of a thermoplastic resin are joined, the seating surface side of the cushion layer is made of a non-woven fabric, and the three-dimensional network structure constituting the cushion layer faces at least in the thickness direction. By having support on two sides, excellent durability, body shape retention,
It is possible to provide a vehicle seat that has an appropriate cushioning property, is hardly stuffy and hard to roll, has good body pressure dispersion, is extremely excellent in riding comfort, and is easily sorted and recycled.

The seat of the present invention is extremely useful not only for vehicles but also for various vehicles such as ships and aircraft. Further, the present invention can be applied to business seats in hospitals and hotels, beds, cushions for furniture, bedding products, and the like.

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Mikiya Hayashibara 2-1-1 Katata, Otsu-shi, Shiga F-term in Toyobo Co., Ltd. Research Laboratory (Reference) 3B096 AD06 AD07 4F100 AK02A AK14B AK41A AK54 AL02 BA04 BA07 BA10B BA10C DG11C DG11D DG14A DG15B EC03A EC03B EC09A GB33 JB16A JB16B JK07A JK17 JL14 4L047 AA21 AB04 BA09 BB06 CA05 CB01 CB08 CC06 CC09

Claims (3)

[Claims] 1. A three-dimensional net-like structure in which a line made of a thermoplastic elastic resin forms a large number of loops, and the loops are entangled and most of the contact portions are joined to each other. A cushion layer having a laminated structure with a non-woven fabric bonded to a fiber made of a non-woven fabric, and a seating surface side of the cushion layer is made of a non-woven fabric, and at least in a thickness direction of the three-dimensional network structure constituting the cushion layer. A vehicle seat having supports on two sides. 2. The vehicle seat according to claim 1, wherein the cushion layer having the laminated structure is wrapped and integrated with a fabric or a nonwoven fabric. 3. The vehicle seat according to claim 1, wherein the thermoplastic elastic resin and the nonwoven fabric constituting the cushion layer are polyester-based resins.