JP2003250667A - Cushion material made of spring structure resin moldings and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive cushion material made of spring structure resin moldings allowing recycle and capable of reducing depressing, preventing its fatigue even after use for many hours, and dealing with many unspecific minute needs such as individual shape and size, having resistance to shock and weight application, and being suitable for seats on which a person sits, sleeps or rides such as seats in an automobile and a motor-bicycle, a sofa or a bed. <P>SOLUTION: This cushion material 10 is shaped by sewing spring structure resin moldings 30 made of fibers 31 with sewing threads 32, 33. Its peripheral fringe is manually sewn with the sewing thread 32. Moreover, a face region is sewn by a sewing machine with the sewing thread 33 to compress the cushion material properly and form rising parts 11 to 14 and depressed parts 10a, 10b on a surface and a rear surface. For example, the rising part is divided into a front part 11, a central part 12, side parts 13 on the right and left sides, and a rear part 14 by the depressed part 10a. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material made of a resin molded product having a spring structure and a method for manufacturing the same, and more specifically, it has excellent impact resistance and load resistance, and also has an individual shape and size. It is possible to meet characteristics and unspecified numerous small needs in each field, seating seats for automobiles, motorcycles, bicycles, trains or airplanes, saddles for horse riding, chairs, sofas, beds, etc. The present invention relates to a cushion material made of a resin molded product having a spring structure that can be applied to anything that sleeps or rides, and a manufacturing method thereof.

[0002]

2. Description of the Related Art At present, urethane foam is mainly used as a cushioning material for seats and beds of automobiles, motorcycles, bicycles, trains, airplanes and the like. Cushioning materials are generally used in some form where people sit, sleep, or ride, whether or not they are accompanied by vibration.In fact, urethane foam is used in all fields. It is widely used, and it is considered that there are few problems in terms of manufacturing method and cost, and the penetration rate is very high.

As such a cushion material, for example,
In Japanese Patent No. 2995325, the seat surface portion is made of high resilience foam having a single layer structure, and the high resilience foam is made of tolylene diisocyanate (TD).
There has been proposed a seat cushion pad for an automobile, which is made of urethane foam and contains I) in an amount of 10% by weight or less, with the balance being isocyanate having diphenylmethane diisocyanate. Also, Japanese Patent No. 2548
No. 477 proposes a cushion structure in which high melting point polyester fibers are fused with a low melting point thermoplastic elastomer. Also, Japanese Patent Laid-Open No. 2000-5101
No. 1 proposes a cushion in which synthetic fibers or natural fibers having a denier of 1 to 20 are partially bonded with a synthetic rubber adhesive or a crosslinkable urethane.

[0004]

However, in general,
When a person sits down, the urethane foam has a problem that the load is concentrated in one place, so that the depression is large and the balance is unstable, and fatigue is accumulated when sitting for a long time. This is because urethane foam is formed by uniformly foaming, so it has a constant density and strength, and it is difficult to change the strength and density from part to part as necessary. . Also, since urethane foam is too flexible, it feels like pushing up from the bottom, bottoming,
There is a large sense of rocking, and sitting for a long time may cause numbness in the legs and a strong feeling of fatigue. For example, in the case of automobiles, the requirements are diversified due to the manufacturing method and structure of urethane, but the density of the material is constant, and in actual use,
Since the surface pressure distribution changes, the function may not be optimal.

Further, since urethane foam is a thermosetting resin, it is difficult to recycle it. As a recycling method, what is made into chips by a pulverizer is adhesively molded into a material called chip foam (ribbon dead foam). It is only regenerated or burned and recovered as heat energy. Landfill treatment and incineration treatment can be mentioned as a disposal method, but the landfill treatment of urethane foam having a low bulk density and softness makes it difficult to stabilize the ground and limits the landfill location. It is also possible to process the material into powder or the like for landfilling, but this requires cost and labor. On the other hand, during combustion, in particular, cyanide, hydrogen chloride, ammonia gas, etc. are generated, so the damage to the incinerator is large, and removal of hydrocyanic acid gas is also expensive. As described above, due to the relationship with the Recycling Law, it is difficult to use urethane foam in terms of environment.

In addition to the above, urethane foam has the following problems. Difficult to clean. This is because the amine catalyst used during production remains in the foam and gives off a bad odor. Further, since it has no air permeability and has heat storage property, it is apt to get stuffy and may start to burn if a concentrated light beam is continuously applied for a long time. Poor environmental performance. Although the expiry date of the CFC substitute used as a foaming agent in the production of urethane foam is 2020, the present situation is that there is no CFC substitute that is superior in foaming performance to the CFC substitute. In addition, TDI, which is an isocyanate usually used in the production of flexible urethane foam, has a concentration of 0.005 according to Ministry of Labor Notification No. 25.
It is a highly toxic substance that has been determined to be less than or equal to ppm, and if it is not thoroughly controlled at the actual manufacturing site, it may endanger the health of workers.

Regarding the characteristics of the flexible urethane foam among the above problems, Japanese Patent No. 29953 of the above-mentioned prior art is mentioned.
Although there is some improvement in No. 25, the problem still remains. Also, Japanese Patent No. 2548477
The cushion structure proposed in No. 1 is difficult to recycle because the high melting point polyester fiber is fused with the low melting point thermoplastic elastomer, and the manufacturing method is complicated and the processing cost is extremely high. ing. Further, Japanese Patent Laid-Open No. 2000-51011 has advantages such as good air permeability and washability, but has problems such as poor durability, complicated manufacturing method, and extremely high processing cost. Further, the rubber-based adhesive and the crosslinkable urethane are thermosetting resins and are not a single composition, so that they are difficult to recycle.

As described above, even though it has various problems as described above, it is equivalent to or more than urethane foam as a cushioning material used for seats and beds of automobiles, motorcycles, bicycles, trains, airplanes, etc. Currently, there is no alternative material that can be manufactured at low cost in addition to the above performance.

In view of the above, the present invention replaces urethane foam, which is difficult to recycle and has the above-mentioned problems in waste disposal, as well as seat sheets for automobiles, motorcycles, bicycles, trains or aircraft, saddles for riding, chairs, etc. An object of the present invention is to provide a cushioning material made of a resin molded product having a spring structure, which is suitable as a cushioning material used for sitting, sleeping, or riding on a person such as a sofa or a bed.
In addition, it is inexpensive, has little sinking, and evenly distributes the pressure when sitting, so it does not fatigue even if it is used for a long time, etc.
A cushioning material that solves various problems of urethane foam, and in particular, is made of a resin molded product having a spring structure that can meet characteristics in each field such as individual shape and size and a large number of unspecified small needs. The purpose is to provide. Further, in manufacturing a cushion material made of the spring structure resin molded product, the molding process is easy, the degree of freedom of the shape is high, and the desired load resistance,
An object of the present invention is to provide a manufacturing method capable of easily manufacturing a molded product having physical properties such as impact resistance.

[0010]

The invention according to claim 1 is
Solid structure and / or hollow continuous filament and / or short filament random loop or curl consisting of a thermoplastic resin, and a three-dimensional structure having voids of a predetermined bulk density formed by contact entanglement of adjacent filaments At least two raised portions are formed on the front surface and the back surface of the body by sewing and compressing the predetermined linear areas of the peripheral edge and the surface area with a sewing line made of thermoplastic resin or the like. A cushion material made of a resin molded product having a spring structure.

"Continuous filaments and / or short filaments" include general-purpose plastics (polyolefin, polystyrene resin, methacrylic resin, polyvinyl chloride, etc.), engineering plastics (polyamide, polycarbonate, saturated polyester, polyacetal, etc.). It is preferably made of a thermoplastic elastomer, for example, an elastomer such as polyethylene (hereinafter referred to as PE), polypropylene (hereinafter referred to as PP), PVC or nylon. In particular, in the case of a hollow continuous line and / or a short line, air is trapped in the tube, and the characteristic of the air spring causes a unique cushioning property, which is preferable. Buckling can also be prevented. The hollow may be continuous or discontinuous. For example, a case where one wire has both a hollow portion and a portion where the hollow portion is closed can be given as an example. The "sewing line" is the same material as the continuous line and / or the short-circuit line (for example, PE,
It is preferable, but not limited to, for example, cotton, etc.).
The sewing line may be solid, but hollow is preferable. The "sewing" is preferably hand-sewn or sewing. For example, it is preferable to form the raised portion in the surface region of the cushion material by sewing the peripheral edge of the cushion material and shaping the cushion material and appropriately performing hand sewing and / or sewing. Alternatively, it is preferable that the peripheral edge of the cushion material be subjected to compression heat molding to be subjected to terminal treatment in advance, and the raised portion is formed by sewing in the surface area of the cushion material. The surface area is an area excluding the peripheral edge. The peripheral edge may be the entire circumference or a part of the circumference. In addition, it is preferable to improve the strength of each portion of the cushion material by applying pressure to the sewn portion and pressing it partially. Further, it is preferable that the front and back (upper and lower) have the same shape, that is, the front and back have a symmetrical structure. Since sewing is performed here, it is possible to finely meet an unspecified number of needs such as sewing an original one according to the body shape of an individual. It is also easier than secondary processing of urethane foam. For example, when it is hand-sewn, it can meet more detailed needs than urethane foam, and the added value of the product becomes high. Further, the strength and the spring characteristics can be freely changed by changing the sewing position, the sewing amount, the type of the sewing line, the sewing mode, and the like. That is, in the case of a material, the strength and the spring characteristics are constant, but since it is possible to squeeze by sewing, the cushion function can be changed and the load distribution can be made variable.

According to a second aspect of the present invention, the thermoplastic resin is a mixture of a polyolefin resin and a vinyl acetate resin, a vinyl acetate vinyl acetate copolymer, or styrene butadiene styrene. Is a cushion material made of a resin molded product having a spring structure. The thermoplastic resin used as the raw material for the spring structure resin molded product is, in particular, a polyolefin resin such as PE or PP, a vinyl acetate resin (hereinafter referred to as VAC), a vinyl acetate vinyl copolymer (hereinafter referred to as EVA), or styrene. A mixture of butadiene styrene (hereinafter referred to as SBS) is preferable. Further, the polyolefin resin may be a recycled resin.

According to a third aspect of the present invention, the mixing ratio of the vinyl acetate content of the polyolefin resin and the vinyl acetate resin or vinyl acetate copolymer is 70 to 97% by weight: 3 to 30% by weight, preferably 80. ~ 90% by weight: 10 to 20% by weight
The cushioning material is formed of the spring-structured resin molded product according to claim 2. When VAC or EVA is 3% by weight or less, the impact resilience is lowered, and when it is 30% by weight or more, the thermal properties are lowered.

According to a fourth aspect of the present invention, the mixing ratio of the polyolefin resin and styrene butadiene styrene is 5
0-97% by weight: 3-50% by weight, preferably 70-9
It is 0% by weight: 10 to 30% by weight, which is a cushion material composed of a resin molded product having a spring structure according to claim 2.

According to a fifth aspect of the present invention, when the continuous filament and / or the short filament has a solid wire diameter of 0.3,
To 3.0 mm, preferably 0.7 to 1.0 mm, and for hollow filaments, 1.0 to 3.0 mm, preferably
It is 1.5-2.0 mm, and is a cushion material which consists of a spring structure resin molding in any one of the Claims 1 thru | or 4. In the case of a solid linear shape, when the wire diameter is 0.3 mm or less, the filament becomes stiff, the number of fused portions increases, and the porosity decreases. When it is 3.0 mm or more, the filament is too stiff, loops or curls are not formed, the number of fused portions is reduced, and the strength is reduced. Moreover, in the case of a hollow filament, 1.0 to 3.0 mm, preferably 1.5 to
When the hollowness is 2.0 mm and the hollowness is 10% or less, it does not contribute to the weight reduction, and when it is 80% or higher, the cushioning property may be deteriorated.

According to a sixth aspect of the present invention, the bulk density of the spring structure resin molded product is 0.001 to 0.08 g / cm.
^3, preferably, 0.008~0.07g / cm ^3, in particular, a spring structure resin molded product according to any one of claims 1 to 5, characterized in that a 0.01~0.06g / cm ³ Is a cushion material. Bulk density 0.00
If it is 1 g / cm ³ or less, the strength decreases. Bulk density 0.0
If it is 8 g / cm ³ or more, the weight cannot be reduced and the elasticity may disappear. Further, it is preferable that the spring structure resin molded product has a constant density and / or a coarse and dense structure as a whole. The bulk density is 0.
001 to 0.03 g / cm ³ , preferably 0.008
~ 0.03 g / cm ³ , especially 0.01-0.03 g / c
m ³ is preferred. 0.0 for dense cushion material
^{3 to} 0.08 g / cm ³ , preferably 0.04 to 0.0
7 g / cm ^3, in particular 0.05~0.06g / cm ³ preferred.

According to a seventh aspect of the present invention, the spring structure resin molded product has a porosity of 91 to 99%, preferably
92 to 99%, especially 93 to 98%.
It is a cushion material which consists of a spring structure resin molding given in either. When the porosity is relatively coarse, the porosity is 96 to 99%, preferably 97 to 99%, especially 9
7 to 98%. If the porosity is relatively dense, 91 to 9
7%, preferably 92-96%, especially 93-94%. The porosity is preferably in the above range in order to maintain the elasticity and strength of the cushion and reduce the weight. [Porosity (%)] = (1- [bulk density] / [density of resin]) × 100

In the invention of claim 8, the mixing ratio of the solid filaments and the hollow filaments is solid: hollow = 0 to 50:50 to 10.
It is 0, and is a cushion material which consists of a spring structure resin molding in any one of Claims 1 thru | or 7. At this time,
It is preferable to use a hollow filament in the central portion and to cover the outer periphery of the hollow filament with a solid filament so that the tactile feel is good.

The invention according to claim 9 is a seat for an automobile, a motorcycle, a bicycle, a train or an aircraft, a saddle for riding, a chair, a sofa or a bed, according to any one of claims 1 to 8. It is a cushion material formed of the resin molded product having the spring structure described above. Besides the above examples,
It can be widely used as a substitute for urethane foam that is used as a cushioning material for people to sit, sleep, or ride, regardless of where vibration is involved or not.

According to a tenth aspect of the present invention, a thermoplastic resin is melted into a plurality of filaments and extruded so that adjacent filaments of random loops or curls of continuous filaments are contact-entangled with each other to obtain a predetermined bulk density. Mold a three-dimensional structure with the voids of
The periphery of the spring structure resin molded product which is the three-dimensional structure is cut out in a U-shape or V-shape, and the cut-out portion is sewn together with a sewing line of a thermoplastic resin or the like, and the surface of the three-dimensional structure is formed. And a predetermined linear region of the surface region of the back surface is sewn with a sewn line of thermoplastic resin or the like, which is a method for producing a cushion material made of a resin molded product having a spring structure. "The end of the spring structure resin molded product which is the three-dimensional structure is cut out in a U-shape or V-shape, and the cut-out end is sewn together with a sewing line of thermoplastic resin or the like." The order of performing the step of "stitching the predetermined linear areas of the front surface and the back surface with sewing lines such as a thermoplastic resin" may be reversed.

[0021] According to the eleventh aspect of the present invention, continuous and / or hollow continuous filaments and / or short filaments of random loops or curl adjacent filaments made of at least a thermoplastic resin are provided on the female mold. Place a three-dimensional structure having a void of a predetermined bulk density formed by contact entanglement, under the temperature conditions necessary to soften the three-dimensional structure, heating the female mold and / or the three-dimensional structure, The three-dimensional structure is clamped by the female mold and the male mold, the spring characteristic is fixed by cooling, and the predetermined linear regions of the front and back surface regions of the three-dimensional structure are sewn with a thermoplastic resin or the like. A method of manufacturing a cushion material made of a resin molded product having a spring structure, characterized in that the cushion material is sewn together with a thread.

[0022]

BEST MODE FOR CARRYING OUT THE INVENTION As shown in the perspective view of FIG. 1, the plan view of FIG. 2 and the rear view of FIG.
Polyolefin resins such as E and PP, and VAC and EVA
Alternatively, a spring structure resin molded product 30 which is a three-dimensional structure molded by using a mixture with SBS (for example, a thermoplastic elastomer) as a raw material is made of PE, PP, PVC, nylon or the like, like the spring structure resin molded product 30. It is shaped by sewing with sewn lines 32 and 33 made of a thermoplastic elastomer.

(Explanation of Spring Structure Resin Molded Product 30)
First, the spring structure resin molded product 30 will be described. Spring structure resin molded product 3 used in this embodiment
0 is a three-dimensional structure having voids formed by randomly intertwining aggregates of continuous filaments and / or short filaments (hereinafter, simply referred to as filaments 31) using the above mixture as a raw material.
Form a plurality of loops or curls (see a partially enlarged view A of FIG. 1). In the present embodiment, the spring structure resin molded product 30 is composed of a hollow wire 31 as shown by the cut surface 31a (see a partially enlarged view B of FIG. 1).

Here, the bulk density of this three-dimensional structure is
0.005-0.03 g / cm3, preferably 0.0
08-0.03g / cm3, especially 0.01-0.03g
/ Cm3 is preferable. The porosity of this three-dimensional structure is 96 to 99%, preferably 97 to 99%.
%, Particularly preferably 97 to 98%. A method for manufacturing the spring structure resin molded product 30 will be described later.

(Description of Cushion Material 10) Next, the cushion material 10 will be described. The cushion material 10 is shaped by sewing the spring structure resin molded product 30. The cushion material 10 in the present embodiment is
It is a cushioning material used for seats in the driver's seat of an automobile.

Specifically, the peripheral edge of the spring structure resin molded product 30 is sewn and / or machine sewn by a sewing line 32 (preferably hand sewn). For example, as shown in the cross-sectional view of FIG. 4 (a) or FIG. 4 (b), the side surface of the spring structure resin molded product 30 is appropriately cut or excavated into a V-shape or U-shape, and the upper and lower ends 30a and 30b thereof are cut. It is preferable that they are overlapped with each other and sewn together with the sewing line 32 (see FIG. 4C). At this time, as shown in the front view of FIG. 4 (d), it is preferable that one sewing line 31 be sewn while moving in parallel in the lateral direction so that the periphery of the spring structure resin molded product 30 makes one round. In addition to cutting or excavating, a cut may be made. The sewing line 32
The sewing line 33, which will be described later, is made of polyolefin resin or polyolefin resin and VAC, EVA or SB.
It is composed of a mixture with S, and is preferably hollow.

Further, the cushion material 10 is sewn and / or hand sewn (preferably sewing) on the surface area with the sewing line 33. For example, the tissue of a predetermined region formed of the inner line 31 is sewn by the sewing line 33 to form the depressions 10a and 10b. Hollow 10a
Is a shape in which a linear portion curved forward from a substantially rectangular shape extends symmetrically. The depression 10b is the depression 1
It is formed to be small in the front-rear direction in the inner front region of the quadrangle 0a.

With the depressions 10a and 10b formed at the sewing-sewn and / or hand-sewn portions, FIG.
As shown in the cross-sectional views of (a) to (c), raised portions 11 to 14 are formed symmetrically on the front and back (upper and lower) in predetermined regions on the front surface and the back surface. Due to the depression 10a, the raised portions 11 to 14 have a front portion 11, a central portion 12, and left and right side portions 1.
3, the rear portion 14 is divided into each area. In addition, the central portion 12 has a raised portion 12a on the left and right due to the depression 10b.
And 12b are formed (see FIG. 5B).

The front part 11 is a part where the back sides of the thighs of both feet mainly come into contact when sitting. The front part 11 is raised so that both feet fit properly, and especially when it is used for a seat of a car (driver's seat), when the driver changes the pedal, the thigh part moves the front part 11 to the left and right. Since it can be slid, it has a structure in which fatigue does not easily occur during operation such as accelerator or brake operation.

The central portion 12 is a portion where the buttocks mainly hit when sitting. The central portion 12 preferably receives most of the weight in a plane and is raised so as to fit the buttocks appropriately. Further, in order to fit more suitably, it is preferable that the recess 10b is provided in the center by sewing and / or hand sewing and is divided into left and right raised portions 12a and 12b.

The left and right side portions 13 are portions where the outer sides of the thighs and buttocks of both feet come into contact. It is preferable that the outer side of the body fits well and that it is raised so as to support the body from the left and right. The side portion 13 also has a role as a frame for maintaining the shape of the cushion material 10 together with the rear portion 14. Here, in order to increase the strength, the rear portion 14 is preferably sewn so as to hold the filament 31 of the entire rear portion 14 by the sewing filament 32 that connects the recess 10a and the peripheral edge (partially enlarged view of FIG. 1). (See Figure C). In addition,
The side portion 13 may also be formed with a peripheral edge by the same sewing method as the rear portion 14 (not shown).

The recesses 10a and 10b are sewn with sewing machine and / or
Or, the tissue is bound by the sewing line 33 sewn by hand,
It has been compressed and has improved strength (see enlarged view D of FIG. 1). As a result, the cushion material 10 is "strained"
It is possible to suitably form unevenness, and to partially strengthen the cushioning material 10 to exhibit a unique spring characteristic. In this embodiment, it is preferable that the number of sewing stitches and / or the number of hand stitches is plural so that they are bound by three sewing stitches, but one stitch may be used.

Since the depressions 10a and 10b are also present on both the front and back surfaces, the cushion material 10 has the same thickness and structure for each of the front and back (upper and lower) parts, and this raised structure has a front and back symmetrical shape. . The symmetry of the front and back sides is characterized in that the raised portions 11 to 14 are formed also on the back side, and exhibits unique suspension characteristics.

For example, a conventional seat using urethane foam has a large road surface reaction force (kickback) which is an unsprung vibration, and therefore a coil spring is often attached to urethane to receive the road surface reaction force. However, in this embodiment, since the raised portions 11 to 14 are formed not only on the front surface but also on the back surface in this manner, the human load can be received by the raised portions 11 to 14 on the front surface side, Unsprung vibration can be received on the back side.
This eliminates the need for a close contact coil spring. Therefore, it is advantageous in terms of weight and structure, is simple, and does not require a special part structure. Since the volume is reduced, the moment of gravity is lowered, which contributes to the stability of the posture. In the case of sprung mass vibration, it is preferable that the spring characteristic is soft.

Further, since the cushion material 10 is made of the spring structure resin molded product 30, the air permeability is excellent. Therefore, needless to say, the cushioning material 1 does not get damp.
If air for heating and cooling is ventilated from the cooling and heating duct in 0, it is possible to meet the specifications of luxury cars without using special materials.

It goes without saying that the cushion material 10 is not limited to the illustrated shape, and can be shaped appropriately. For example, the number of divisions of the rising part may be appropriate,
The present invention is not limited to this embodiment. Alternatively, only the depressions on the left and right vertical line portions may be used. Further, it may be only left-right symmetry or front-back symmetry only. In particular, it is possible to express even complex irregularities and subtle changes that are difficult with conventional molding, and it is possible to meet product requirements, characteristics and unspecified numerous small needs in each field such as individual shape and size. is there. Further, as another embodiment, a spring structure resin molded product 30 is previously prepared.
It is also preferable that after compression-molding into an arbitrary shape, further details (for example, a raised portion or the periphery) are formed by sewing. According to this method, for example, it is suitable for a cushion material used for a seat of a motorcycle. Details will be described later.

(Manufacturing Method of Spring Structure Resin Molded Product 30) Next, an example of a manufacturing method of the spring structure resin molded product 30 will be described. As shown in the schematic view of FIG. 6, a spring structure resin molded product 30 according to the present embodiment.
In the manufacturing method of 1, the polyolefin resin such as PE or PP and the raw material resin such as VAC, EVA or SBS are preferably dry blended through a tumbler or a constant amount feeder described later, or mixed or melted. It is mixed and pelletized, and then sent to the hopper 21 of the extruder 20.

Specifically, raw material resins such as PP and S
BS with a tumbler (KR mixing machine manufactured by Kato Riki Seisakusho),
Mix for 15 minutes at 40 rpm.

Next, as shown in the perspective view of FIG. 7, the mixture of the raw material resins is charged from the hopper 21 of the φ65 m single-screw extruder 20 to a predetermined temperature (Examples 1 to 6 are 2).
Melted and kneaded at 00 ° C., 260 ° C. in Examples 7 to 9), melt-extruded at a predetermined extrusion speed from a large number of nozzles of a predetermined diameter provided in the molding die 22, and then taken out by a take-up machine 23 described later, Wire diameter (for example, 600 to 9)
10,000 denier, preferably 3,000 to 30,0
00 denier, more preferably 6,000 to 10,0
00 denier) to form solid and / or hollow continuous filaments, and the molten filaments 31 have, for example, a diameter of 1 to 10
mm, preferably forming a loop with a diameter of 1-5 mm,
Random loops are formed by contacting and entanglement between the adjacent filaments 31 and the inside of the bus 25 (in water). At this time,
At least some of the contact entangled portions are melt-bonded to each other. The filaments 31 may be hollow and solid filaments mixed in a predetermined ratio.

The thickness and bulk density of the three-dimensional structure which is a set of the above-mentioned random loops are set between the take-up rolls 24 of the take-up machine 23 in the bath 25. This three-dimensional structure (for example, thickness 10 to 200 mm, width 2,000 m
m) is randomly formed into a curl or a loop, is solidified in water, and is taken out as a spring structure resin molded product 30 by the winding rolls 26 and 26.

When the filament 31 having the loop formed in water is pulled by the pulling machine 23, the cushion characteristic may be changed by changing the speed of the pulling machine 23. In that case, when relatively increasing the bulk density of the three-dimensional structure, 0.03 to 0.08 g / cm 3, preferably 0.04 to 0.07 g / cm 3, particularly 0.05.
It is preferably set to 0.06 g / cm 3. Moreover, when reducing the porosity of this three-dimensional structure, 91-97
%, Preferably 92 to 96%, particularly preferably 93 to 94%.

Further, for example, the take-up rolls 24, 24
By adjusting the take-up speed of the take-up machine 23 to a low speed at a predetermined interval (for example, 3 to 5 m), for example, the take-up speed of the take-up machine 23 is set to a low speed within a set time by a timer or the like. In the longitudinal direction of 30, a portion having a large bulk density formed at low speed pulling and a portion other than that, that is, coarse and fine may be continuously formed at predetermined intervals (for example, 30 to 50 cm).

Further, as shown in the front view of FIG. 9, upon taking-up, the spring structure resin molded product 3 which is a three-dimensional structure.
When it is difficult to bend 0 with the take-up rolls 24, 24, it is also possible to bend at that portion by raising a portion having a high bulk density and pull it up from water. The spring structure resin molded product 30 taken out through the above steps is cut by a cutting device 27 to an appropriate length. The bath 25 is provided with a water supply valve and a drain valve (not shown).

As another example, as shown in the front view of FIG. 9, when the cutting device 127 is provided in the bus 125, the cutting device 127 is arranged near the lower part of the take-up machine 123,
On the opposite side wall of the bus 125, there is provided a transfer device 128 including a conveyor having a plurality of locking protrusions that are inserted into a single space cut at the cutting site. For the configuration of the other parts, the above description is cited as the 100s.

By the above manufacturing method, as an example, a spring structure resin molded product 30 having a bulk density of 0.03 g / cm ³ and a thickness of 50 mm was obtained. The three-dimensional structure can also be manufactured by using one or a combination of a plurality of different materials.

(Examples) (1) Manufacturing Examples with Different Mixing Ratios PE + VAC, PE + EVA, PP + SB
In S, blending was performed while changing the compounding ratio, and a three-dimensional structure as a base of the cushion material 10 was created. In addition,
The blend is a KR mixer manufactured by Kato Riki Seisakusho (model: KR
T-100) tumbler was used for 15 minutes at 40 rpm. For the molding, use a φ65 mm single screw extruder.
With a screw rotation speed of 60 rpm, a take-up speed of 3.1 m /
It was collected at a rate of 0.6 m / min. The resin temperature of the mixture is 200 ° C. The compounding ratio is shown in "Table 1," the manufacturing conditions are shown in "Table 2," and the product specific values such as bulk density are shown in "Table 3." Examples 1-3: PE + VAC Examples 4-6: PE + EVA Examples 7-9: PP + SBS

[0047]

[Table 1] Compounding ratio of Examples 1 to 9

[0048]

[Table 2] Manufacturing conditions of Examples 1 to 9

[0049]

[Table 3] Product-specific values of Examples 1 to 9

(2) Production Examples Different in Bulk Density Next, a mixture of PE: VAC = 90: 10 was used,
A three-dimensional structure as a base of the cushioning material 10 having a different product bulk density was prepared. In addition, as in (1), the blending is performed by a KR mixer manufactured by Kato Riki Seisakusho (model: KRT-10
0) Using a tumbler, it was carried out at 40 rpm for 15 minutes.
For the molding, a φ65 mm single screw extruder is used, the screw rotation speed is 60 rpm, the take-up speed is 3.1 m / min,
It was collected at 0.6 m / min. The resin temperature of the mixture is 2
It is 00 ° C. The compounding ratio is shown in "Table 4," the manufacturing conditions are shown in "Table 5," and the product specific values such as bulk density are shown in "Table 6." Examples 10 and 11: PE + VAC

[0051]

[Table 4] Mixing ratio of Examples 10 and 11

[0052]

[Table 5] Manufacturing conditions of Examples 10 and 11

[0053]

Table 6 Product-specific values of Examples 10 and 11

(3) Comparative Example 1 A soft urethane foam, which is a mainstream material as a conventional cushion material, is used as Comparative Example 1. The manufacturing conditions and product characteristics of the flexible urethane foam are shown in "Table 7". Comparative Example 1: Urethane foam

[0055]

[Table 7] Main raw materials and production conditions of Comparative Example 1

(4) Comparative Examples 2 to 4 The starting resin was PP only, and the three-dimensional structure was prepared by changing the bulk density. Molding is performed using a φ65 mm single screw extruder with a screw rotation speed of 60 rpm and a take-up speed of 0.6 m.
/ Min, 1.0 m / min, 3.1 m / min. The resin temperature is 260 ° C. The compounding ratio is shown in "Table 8," the manufacturing conditions are shown in "Table 9," and the product specific values such as bulk density are shown in "Table 10." Comparative Examples 2 to 4: Conventional three-dimensional structure (PP only)

[0057]

[Table 8] Compounding ratio of Comparative Examples 2 to 4

[0058]

[Table 9] Manufacturing conditions of Comparative Examples 2 to 4

[0059]

[Table 10] Product specific values of Comparative Examples 2 to 4

(Test Example) In the test, the following items are clarified. (1) Test example 1 Compression characteristics (2) Test example 2 Cyclic residual compression strain (3) Test example 3 Rebound resilience

(1) Test Example 1 The compression characteristic test was carried out in accordance with JIS K 6400 flexible urethane foam test method appendix (reference) 1. The test piece size is (W) 300 × (L) 300 × (T) 50.
Load-compression deflection rate diagrams are shown in FIGS. 10 to 24.

The three-dimensional structure which is the base of the cushioning material 10 of all Examples and the urethane foam of Comparative Example 1 are compared. All examples do not have the significant yield points found in Comparative Example 1. Having no significant yield point means that
It is shown that the cushion structure has a small local depression, and the load can be evenly received over the entire region in contact with the cushion structure.

Next, in Comparative Example 1, the deflection rate is 50%.
After that, the rising of the load is seen, but it is not seen in all the examples. Further, it is effectively deformed up to about 90% of the structure thickness. This indicates that the feeling of bottoming is small. It also shows that the structure recovers quickly when unloading, and it has sag resistance.

Next, a comparison will be made between the three-dimensional structures which are the bases of the cushioning material 10 of all the examples and the conventional three-dimensional structures which are the PPs of Comparative Examples 2 to 4. Comparative Example 2 has a yield point, a high load, causes plastic deformation, and the structure does not elastically return. Comparative Examples 3 and 4 have no yield point,
After the deflection rate of 50%, the load rises and a bottom feeling is exhibited. In addition, it causes plastic deformation and does not recover elastically.

In this embodiment, the cushioning material 10 having a desired hardness can be manufactured by changing the mixing ratio or bulk density of the three-dimensional structure.

(2) Test Example 2 A repeated compression residual strain test was conducted in accordance with JIS K 6400 flexible urethane foam test method 8.1A. The test piece dimensions are
(W) 300 x (L) 300 x (T) 50. The test object is Example 2 (PE + VAC, bulk density 0.03 g /
cm ³ ), Comparative Example 1, Comparative Example 3 (PP, bulk density 0.03
The squeezing test was performed at g / cm ³ . The results are shown in "Table 11".

[0067]

[Table 11] Repeated compression residual strain measurement results

Example 2 and Comparative Example 1 showed almost the same performance. Although the structures of Example 2 and Comparative Example 3 are the same and only the resin is different, Comparative Example 3 which causes plastic deformation is significantly reduced to 75%. The product of the present application has the same sag resistance as urethane foam.

(3) Test Example 3 The impact resilience test was conducted according to JIS K 6400 flexible urethane foam test method 9.2B method. The test piece dimensions are
(W) 300 x (L) 300 x (T) 50. The test target is the same as in Test Example 2. The results are shown in Table 12.

[0070]

[Table 12] Measurement result of impact resilience

Example 2 showed a high impact resilience of 91%. Compared to urethane foam, the product of the present application has 1.4 times the resilience performance.

(Other Embodiment of Cushion Material 10) FIG. 2
5. Like the cushion material 110 shown in the perspective view of FIG. 5, the spring structure resin molded product 30 is previously compression-heat molded into an arbitrary shape and subjected to end treatment (peripheral treatment), and then a predetermined linear region of the surface region is sewn. Therefore, it is also preferable to additionally form unevenness (for example, a raised portion or the periphery). Here, the sewn line 133 forms a depression and a raised portion on the front surface and the back surface of the cushion material 110. The cushion material 110 here is a cushion material mainly used for a seat of a motorcycle (for example, a motorcycle).

The cushion material 110 is provided with a multilayer sheet having the same or different spring characteristics (for example, a two-layer structure of the upper sheet 102 and the lower sheet 103) and is fixed to the base 104. At this time, it is preferable that the upper sheet 102 and the lower sheet 103 are bonded to each other with an adhesive or a double-sided tape. The spring characteristics can be varied for each sheet or portion depending on the density, material and / or wire diameter of the spring structure resin molded product 30. Cushion material 11
0 may be a single layer.

In this embodiment, the upper sheet 102 is lower in rigidity and flexible than the lower sheet 103. This is because the buttocks and the like directly touch the upper sheet 102 with respect to the lower sheet 103 fixed to the base 104. At this time, the upper seat 102 is sewn so that the upper seat 102 can be appropriately fitted to the riding posture of a person.
It is preferable to form a raised portion appropriately. On the other hand, since the lower sheet 103 is fixed to the base 104, it needs to be harder than the upper sheet 102. Also, the upper sheet 102
The lower sheet 103 and the lower sheet 103 may be sewn together. Further, the cushion material 110 is preferably a multilayer, but may be a single layer.

As described above, by further sewing after compression heat molding, it is possible to express even complicated irregularities and subtle changes which are difficult to obtain by conventional molding, and to express individual shapes and sizes. It is possible to more strictly meet the product requirements, characteristics, and unspecified numerous small needs in the field, and it is also possible to custom-make according to the vehicle type and body type. For example, when it is used as a seat for motorcycles, automobiles, etc., it is possible to meet the demands of drivers (for example, people who use it) who are particular about driving posture,
It is possible to provide a seat that accurately fits the driving posture and driving motion of each person. In addition, the added value of the product can be increased.

For example, the cushion material 110 is compression-heat molded by the following steps. Here, with reference to FIGS. 26 to 29, an example of a method for manufacturing the cushion material 110 through the compression heating molding step and the sewing step will be described.

(1) Loading Process FIG. 26 is a side sectional view for explaining the first stage of the compression heat molding process of the cushion material 1. As shown in the explanatory view of FIG. 26, a female mold 111 made of concrete (hereinafter simply female mold 111)
One or more resin molded articles 30 having a spring structure are placed on the cavity 112 of FIG. At this time, two or more spring structure resin molded products 30 having the same or different spring characteristics may be placed at the same time. As described above, the spring structure resin molded product 30 is a three-dimensional structure having voids formed by randomly intertwining filaments 31. The filaments 31 form a plurality of loops or curls ( (See a partially enlarged view E of FIG. 26).

In this manufacturing method, a temperature higher than the softening point of the raw material resin forming the filaments 31 of the spring structure resin molded product 30 is required, and therefore the cavity 1 of the female mold 111 is required.
Hot water (preferably 70 ° C. or higher) is put into the hot water supply device 113 from the hot water supply device 113, and the spring structure resin molded product 30 is heated and softened. I used hot water here
This is for heating the spring structure resin molded product 30 from the inside of the female mold 111. Further, the female die 111 itself may be heated by a heater or the like. At this time, it is preferable to embed a heat conductor (for example, a heater) in the concrete of the female mold 111. In order to enhance the heat retention effect, it is also preferable to cover the periphery of the female mold 111 with a heat insulating material (for example, a container of wood, foamed resin, or the like). In addition, when it is necessary to heat the air around the filaments 31 (including the air in the hollow portion in the case of a hollow filament) that constitutes the spring structure resin molded product 30, molding should be performed with the heat retention residual heat of the female mold 111. Is also preferable. Further, instead of the hot water supply device 113, the steam may be heated by the steam supply device 117 or the like. When steam is used, for example, a steam injection hole is formed in the female mold 111, and steam is injected into the cavity 112 through the steam injection hole. It is preferable to inject steam and heat at the mold clamping stage. This is preferable because the heat becomes uniform and the molding can be performed at a higher temperature. In addition, there are molded products that require not only heating but also pressure. In this case, heating and pressing with steam can be performed. Since some shapes cannot be heated mechanically, it is possible to handle complicated shapes by using atmospheric pressure.

In this female mold 111, for example, a mold of a product is molded with an appropriate material such as plaster, the mold is turned upside down, and a plate is horizontally fixed below. It is manufactured by coating a mold release agent on, kneading concrete powder with water, dropping it into a mold to solidify it, and releasing from the mold. After the concrete has hardened, the mold 111 and the plate are removed upside down to complete the female mold 111. At this time, the strength, rigidity and thickness of the concrete can be adjusted by forming a space under the plate on which the formwork is placed, and moving the plate up and down to adjust the space. For example, when increasing the thickness of concrete, the plate fixing position is lowered. As described above, concrete is excellent in moldability and can be produced by simply kneading and pouring it into a mold, and thus the cost of the female mold 111 itself is reduced (for example, 1/50 to 1/10 of that of a conventional mold).
0), it is possible to manufacture the female mold 111 having a complicated shape, and it is possible to easily duplicate the same product, which improves accuracy. For example, the same size can be measured when the female die 111 is manufactured. Further, since concrete is easily adapted to a product, it is possible to form the cushion material 10 smoothly as if the surface of the cushion material 10 was polished by just clamping the mold. Further, the pattern of the mold can be taken, and for example, by applying vinyl and clamping the mold, it is possible to perform surface processing such as applying a pattern to the surface based on the degree of surface roughness of vinyl. In addition, since the female mold 111 is made of concrete, it can suitably withstand the pressure applied during the molding of the cushion material 10 and has high durability, so that it can be used tens of thousands of times. The weight of the female mold 11 is preferably 50 to 100 kg.

The female mold 111 is preferably concrete, but is not limited to this, and may be made of a composite synthetic resin material such as metal or fiber reinforced plastic (FRP). In addition, if the existing mold for urethane foam manufacturing equipment is improved slightly, such as trimming, margin and designing the extension rate, the existing equipment can be used. You don't even have to.

The male mold 114 includes a base 104 and a male mold stand 114.
and a. The male mold 114 is fixed to the tip of the pantograph jack 115 at a plurality of locations by a fixture,
With the pantograph jack 115, the spring structure resin molded product 30 on the cavity 112 of the female mold 111 is clamped from above. The male mold 114 is preferably capable of withstanding a pressure of 10 tons or more. In this embodiment, 1
By installing a plurality (for example, three) pantograph jacks 115 for one male mold 114, the load pressure is improved and the load is distributed at a plurality of positions (for example, three positions). The pantograph jack 115 may be manually operated, but may be automatically operated by appropriately attaching a motor 115a. The upper end of the pantograph jack 115 is fixed to the upper base 118, and the upper base 118 is fixed to the upper part of the female mold 111 by the support 119. By using the pantograph jack 115, the equipment can be simplified and the cost can be reduced. However, instead of the pantograph jack 115, a hydraulic cylinder, a pneumatic cylinder or the like may be used.

The upper and lower positions of the female mold 111 and the male mold 114 can be reversed. With this configuration, the own weight of the female mold 111 made of concrete is used as a weight instead of the weight, and compression heating molding can be performed using the own weight. In this way, if the heavier one is used as the upper mold (pressurizing side), compression heating molding can be performed by utilizing the own weight of the upper mold. For example, the upper mold may be heavy concrete, the lower mold may be lightweight concrete, the upper mold may be large, and the lower mold may be small. When the mold is clamped by its own weight using gravity, the pantograph jack 115 may be unnecessary. For example, the upper mold may be suspended by a balancer made of a spring material or the like, or the upper mold and the lower mold may be joined by a hinge or the like and the upper mold may be opened to a predetermined angle to clamp the mold.

As the male mold 114, it is preferable to use the base 104 which is a part of the product. Base 104
Is attached by fitting the back surface to the lower surface of the male base 114a. The upper surface of the male base 114a is fixed to the pantograph jack 115 by a fixture. As described above, since a part of the product (base 104) constitutes a part of the manufacturing apparatus (male mold 114), the mold to be prepared is only the female mold 111, and it is not necessary to separately manufacture the male mold 114. . Conventionally, in a mold for urethane foam molding, it is necessary to manufacture a male mold and a female mold separately from the product, but in this manufacturing method, since the male mold 114 itself is a part of the product,
It eliminates the need for a stand, punch, etc., enabling cost reduction and improving molding accuracy.

(2) Mold Clamping Process FIG. 27 shows the second step of compression heating molding of the cushion material 110.
It is a side surface sectional view explaining a step. As shown in the explanatory view of FIG. 27, the pantograph jack 115 pushes down the male mold 114 (also used as the base 104 in this case) as shown by the arrow in the drawing, and clamps the mold. Here, it is preferable that the cavity 112 of the female mold 111 is set to a size for deep drawing. Since the mold has a margin, the stroke can be made deep or shallow, and the thickness of the cushion material 110 can be made variable by adjusting the stroke of the diaphragm. Therefore, the thickness of one mold can be varied. Also, naturally, the density is also variable. In this way, male 114
By making the stroke of variable, it is possible to manufacture with either one type of deep drawing and shallow drawing, and it is possible to freely change the density, spring characteristics, and rigidity.

In particular, as shown in the figure, if the inclination angle (taper) of the side surface of the female die 111 is reduced (it is almost vertical in the figure), the thickness of the cushion material 110 can be easily adjusted with one die. For example, the inclination angle is 1/50 to 1/400 (for example, 1/200). The inclination may be either inward or outward with respect to the vertical downward direction. If it leans inward too much, it may be difficult to control the stroke. As a result, one mold can meet the required product characteristics of various cushion materials 1. In particular, even for the same product, the thickness of the cushion material 110 can be arbitrarily selected. For example, it is possible to easily meet a large number of unspecified small needs, such as being made to order.
In addition, in the part where the inner side of the thigh is in contact, the compression ratio may be increased and the spring characteristics may be hardened. This has advantages such as improved cushioning properties and durability.

In addition, when the spring structure resin molded product 30 is clamped by the female mold 111 and the male mold 114, the heating temperature is changed stepwise so that the rigidity is partially changed. You can also do it. At this time, it is preferable to heat the edge portion to form a hard plate. For example, it is preferable to form a curled edge portion into a plate shape when trimming. This edge portion can be suitably fitted to the base 104. The edges are
It is preferable that the base 104 is once expanded and then hooked to the base 104, and then restored by elastic force so as to be fitted and attached. With such a structure, the cushion material 110
It is also possible to attach and detach the base 104 and the base 104 without engaging with a stapler or the like.

Further, when the spring structure resin molded product 30 is clamped by the female die 111 and the male die 114, the female die 11
There is also a case where hot burning of No. 1 is performed, the temperature of the mold is raised, and the surface portion is welded to be hardened by epidermis (skin) molding. Since only the surface of the spring structure resin molded product 30 can be melted to form a skin, it is not necessary to perform coating (eg, covering with vinyl leather 105 or the like) in a post-process. For example, it can be used for molding a resin of an instrument panel. That is, the surface of the spring-structured resin molded product 30 may be melted in the mold to form a grain, and at the same time, integrally molded. In addition, it is particularly preferable to form the skin by hot burning when it is necessary to prevent the cushioning material 110 from unraveling, to be waterproof, or to appropriately protect the material.

(3) Trimming Step FIG. 28 shows a third step of the compression heat molding step of the cushion material 110.
It is a top view explaining a step. As shown in the explanatory view of FIG. 28, after the mold clamping state is maintained for a predetermined time, the thermal cutter 11
In step 6, the burr 32 (see the partial enlarged view F of FIG. 28) protruding from the end of the male mold 114 is trimmed along the periphery of the male mold 114, and at the same time, the end is heat-welded. Conventionally, the trimming process of the terminal has been difficult because the shape has been adjusted by trimming and the like after re-dimensioning after molding. With this method, trimming can be easily performed. In particular, trimming at this stage eliminates the unraveling of the terminal, and there is no need to dimension the terminal later, so that the processing is simple and the sewing is easy.

(4) Mold Release Step Cooling water is poured into the cavity 112 of the female mold 111 to solidify the spring structure resin molded product 30. The molding time can be shortened by adding water and quenching instead of gradually cooling. Then, after the curing time has elapsed, the mold is released. As a factor for determining whether or not it is solidified, it is in a solidified state if the pantograph jack 115 is loosened and there is no springback. Hereinafter, heating / cooling of the female mold 111 and / or the resin molded product 30 having the spring structure is repeated. In the case of a hollow filament, springback can be prevented by satisfying an appropriate thermal equilibrium condition considering the air in the hollow portion. Note that it is preferable to cool by the above method, but it is also possible to adopt a configuration of cooling naturally without using cooling water.

At this time, if the female mold 111 is made of concrete, the raw material resin does not melt and adhere to the female mold 111, and a mold release agent is unnecessary. The conventional metal mold has a drawback that the temperature rises remarkably and the raw material resin easily adheres to the mold. Therefore, a release agent is indispensable for the production of urethane foam, and it takes time and effort to produce it. In addition, if the product is made of concrete, it is easy to be familiar with the product, so that it has an excellent ability to duplicate the same product and can form a complicated shape.

(5) Final Step The cushion material 110 formed through the compression step is
The sewing line 133 is sewn by the above-described sewing method to additionally form irregularities (for example, depressions or raised portions). After that, as shown in the attachment explanatory view of FIG. 29, the action material 110 is placed on the base 104 and fixed. Heat-molded vinyl leather 105 is placed on the base 10
Stop at 4 with a stapler. You may adhere with double-sided tape. Further, by forming a convex portion (or concave portion) on the lower sheet 102 in the molding process and fitting and fixing the concave portion (or convex portion) appropriately provided on the base 104, a stapler or a double-sided tape becomes unnecessary. Become. Further, the upper sheet 102 and the lower sheet 103 can be appropriately adhered by an adhesive or a double-sided tape or the like to prevent the slippage. Upper sheet 1 as above
02 and the lower sheet 103 are provided with irregularities, and the upper sheet 10
2 and the lower sheet 103 can be fitted and fixed. However, in this step, when the vinyl leather 105 or the like is covered, the upper sheet 102, the lower sheet 103, and the base 104 may not be particularly fixed.

Since the cushion material 110 made of the spring-structured resin molded product 30 in this embodiment has air permeability, it may be better not to cover the vinyl leather 105 or the like in the subsequent step. In this case, the spring structure resin molded product 30 may be entirely sewn around, or may be covered with a net. The net used here is preferably made of the same material as the sewing lines 32 and 33, particularly a water-repellent material (for example, plastic). As a result, the air permeability is appropriately ensured, which is particularly effective in areas and seasons with high humidity. It is also suitable as a seat for cars that run on sand such as buggies. In addition, since the spring structure resin molded product 30 is prevented from unraveling and is preferably protected, it is also excellent in durability. In addition, the vinyl leather 105 may be put on after the net is put on. This is to prevent foreign matter from entering due to mischief or the like in a seat such as a vehicle on which an unspecified large number of people ride.

(Other Embodiments of Spring Structure Resin Molded Product 30) Next, other examples than the spring structure resin molded product 30 of the above embodiment will be described. Various molding methods that utilize the viscoelastic behavior of the raw material resin are utilized.

In the manufacturing process of the spring-structured resin molded product 30, the take-up speed and the heat increase / decrease
It is possible to arbitrarily form a three-dimensional structure having different cushioning characteristics for each part. For example, like the spring structure resin molded product 130 shown in FIG. 30A, the cushion characteristics can be gradually softened from the outer periphery toward the center in a predetermined range or gradually. Here, a hard portion 130 is formed on the outer circumference.
A soft portion 130b is formed at a and the central portion.
In addition, the spring structure resin molded product 2 shown in FIG.
It is also possible to make the cushion characteristic of the central portion hard, as in 30. Here, a hard portion 230a is formed at the center and a soft portion 230b is formed at the outer periphery. Also, FIG.
As in the spring structure resin molded product 330 shown in 0 (c), the cushion characteristics can be partially changed. Here, the hard portion 330a is partially formed in the soft portion 330b (for example, two places).

For example, a spring structure resin molded product 130.
If so, it is preferable as a cushion material for a motorcycle seat. By making the side surface of the cushion material 1 hard, when the vehicle is driven by sandwiching the seat, the cushion material 1 is suitably fitted to the inner thighs of the driver and the running stability is improved. Further, the spring structure resin molded product 230 is suitable for a cushion material for a helmet and the like. Like this one
The surface (the part in contact with the head) is soft with a three-dimensional structure,
By molding the inside hard, it is possible to manufacture hats (sunshades, helmets, etc.) whose hairstyle does not collapse easily. This is preferable because it enables to shade and has good air permeability.

Depending on the load and the amount of bending, some cushioning materials may be sufficient if only the surface is hard. In such a case, in addition to partially changing the density with a single three-dimensional structure as described above, a plurality of thin three-dimensional structures with different densities are manufactured, and by stacking them in various ways, A spring structure resin molded product can also be formed. According to this method, the amount of the raw material resin used can be reduced, and it is preferable in terms of productivity. For example, like a spring structure resin molded product 430 shown in FIG. 31A, a three-dimensional structure 430a having a low bulk density is stacked below the three-dimensional structure 430a, and a three-dimensional structure 430c having a further low bulk density is stacked below the three-dimensional structure 430b. Then, one spring-structured resin molded product 430 can be formed by bonding them together.

Further, as in the spring-structured resin molded product 530 shown in FIG. 31B, the holes 5 are formed by partially melting with heat.
Partial reinforcement can also be achieved by forming 30a (partition block molding). The hole 530 may be formed at a stage before compression heating molding or sewing, or may be formed at a stage after compression heating molding or sewing. In addition, FIG.
As shown in (c), a stopper 53 such as a metal fitting is provided in the hole 530a.
It is also possible to insert 0b. The stopper 530b may be inserted before compression heat molding or sewing, or may be inserted after compression heat molding or sewing.

The wire diameters of the wire rods 31 forming the spring structure resin molded product 30 do not necessarily have to be equal. 1
Even with three cushion materials, the way the load is applied differs depending on the location. In order to partially harden that range, in addition to changing the bulk density, it is also possible to change the thickness and hardness of the filament 31 itself that constitutes the spring structure resin molded product 30. For example, it is preferable to use a thick line or a line having a high resin hardness at a location where the load applied to the buttocks is concentrated.

At this time, in order to partially manufacture the thick line, as shown in FIG. 32 (a), the forming die 622 is used.
It is preferable that the diameter of the nozzle opening 622a is partially (for example, central portion) larger than that of the normal nozzle opening 622b. As shown in FIG. 32 (b), this molding die 622
In that case, the thick filament 631 is extruded partially (for example, from the central portion) at the same time as the ordinary filament 31 to be extruded. This allows the rigidity to be changed in a complex manner. Also, by changing the material of the filaments 31, it is possible to mold a soft or hard cushion material having the same thickness and bulk density. For example, in the case of a cushion material for a seat of a motorcycle, various materials can be selected according to the weight of a rider, and added value can be added to the product.

Further, the spring structure resin molded product 30 can be hybrid-molded by entwining various materials such as fibers and wires. As a result, it is possible to reinforce the weak points of the resin, which are weak against heat, weak against buckling, weak against pulling, and the like, which are entangled therein. For example, FIG. 33 (a)
It is preferable that a plurality of wires 733 are entwined with the filament 731, as in the spring structure resin molded product 730 shown in FIG. Further, as shown in the cross-sectional views of FIGS. 33B and 33C, the wire 733 and the like are not only entangled with the line 731,
It is also preferable to pass the hollow portion of the filament 731.

[0101]

EFFECTS OF THE INVENTION The cushion material made of the resin molded product having the spring structure described in claims 1 to 9 has the following effects.

The cushion member made of a resin molded product having a spring structure is excellent in durability and sag resistance, has a small local depression, and does not have a feeling of bottoming or rocking. Further, when sitting down, the load can be evenly received and the pressure can be dispersed over the entire part that comes into contact with the body, so that fatigue is unlikely to occur even after long-term use, and sitting comfort is improved. In particular, since each piece is carefully sewn and shaped, it is possible to successfully express irregularities that were difficult with conventional molding.
As a result, it is possible to freely process the details such as individual shapes and sizes such as shaping the original ones according to the body shape of the individual, and it is possible to meet the product requirements and characteristics in each field. At the same time, it can respond to many unspecified needs. For example, when used as a seat for automobiles, etc., it can accurately meet the driving posture and driving behavior of each person, which can meet the demands of drivers (for example, people whose occupation is that) who are particular about driving posture. A seat can be provided. It is also easier than secondary processing of urethane foam. For example,
If it is hand-sewn, it can meet more detailed needs than urethane foam and add value to the product.

The cushion member made of a resin molded product having a spring structure can be sewn and pressed to improve the strength of each portion. That is, the strength and the spring characteristics can be freely changed by changing the sewing position, the sewing amount, the type of sewing line, the sewing mode, and the like. Therefore, although the strength and spring characteristics of the material are constant, the material can be squeezed by sewing, so that the cushion function can be partially changed and the load distribution can be made variable.

Since the cushion member made of a resin molded product having a spring structure has a structure for the front and back sides, it is possible to suitably receive vibration. As a result, the contact coil spring, which is conventionally installed under the seat of an automobile or the like as a kickback measure, becomes unnecessary. Therefore, in terms of weight,
The structure is advantageous, the structure is simple, and the center of gravity is lowered, so that the stability of the automobile is improved.

Since the cushion material composed of the spring structure resin molded product is a structure having completely continuous voids,
Excellent breathability. Therefore, it does not get damp. Further, since the air for cooling and heating can be ventilated from the cooling and heating duct through the cushion material, it is possible to provide the seat and the like of the automobile with the cooling and heating function. As a result, it is possible to suitably cope with high-end vehicle specifications without equipping special materials. In addition, it is strong against water, and there is no problem even if it gets wet with rain. Therefore, it can be washed with water and dried quickly.

The cushion material made of a resin molded product having a spring structure is a high-value-added product made of a resin such as PE which is a recycled resin for reuse of thermoplastic resin edible oil packaging containers and discarded agricultural plastic films. It can be regenerated and can be regenerated any number of times by remelting the cushion material itself, which is a resin molded product having a spring structure. In this way, it is excellent in recyclability and considers the environment after use. Also,
Since recycled resin can be used, it can be manufactured at low cost.

According to the method of manufacturing a cushioning material made of a resin molded product having a spring structure according to the tenth aspect of the present invention, the spring has an easy molding process and has desired physical properties such as load resistance and impact resistance. A cushion material made of a structural resin molded product can be easily manufactured. In particular,
Since highly toxic raw materials such as TDI used in the production of urethane foam are not used, no toxic gas is generated during production and the working environment is good.

From the above, the cushioning material made of the resin molded product of the spring structure in the present invention can be used for seating seats of automobiles, motorcycles, bicycles, trains or airplanes, riding saddles, chairs, sofas, beds, etc. It can be suitably used as a substitute for a conventional urethane foam in a place where a person sits, sleeps, or rides with or without.

The embodiment of the cushion material made of the resin molded product having the spring structure according to the present invention is not limited to the above, and various forms can be adopted within the technical scope of the present invention. . Further, modifications and the like can be added without departing from the technical idea of the present invention, and modifications and equivalents thereof are also included in the technical scope of the present invention.

[Brief description of drawings]

FIG. 1 is a perspective view of a cushion material 10.

FIG. 2 is a plan view of a cushion material 10.

FIG. 3 is a back view of the cushion material 10.

FIG. 4A is a partial cross-sectional view of the cushion material 10 (spring-structured resin molded product 30) in the process of cutting the end portion;
(B) is a partial sectional view in the other end cutting process, (c)
Is a cushion material 10 (spring structure resin molded product 30)
FIG. 3D is a partial cross-sectional view of FIG.

5A is a sectional view taken along line VA-VA in FIG. 2, FIG. 5B is a sectional view taken along line VB-VB in FIG. 2, and FIG. 5C is VC-VC in FIG.
It is a line sectional view, showing only the outline and omitting the net-like structure.

FIG. 6 is a schematic view showing steps of a method for manufacturing a spring-structured resin molded product 30.

FIG. 7 is a perspective view showing a method for manufacturing a spring structure resin molded product 30.

FIG. 8 is an embodiment showing another method of manufacturing the spring structure resin molded product 30.

FIG. 9 is an embodiment showing still another method of manufacturing the spring structure resin molded product 30.

10 is a graph showing a load-compression deflection ratio of Example 1. FIG.

11 is a graph showing a load-compression deflection ratio of Example 2. FIG.

12 is a graph showing a load-compression deflection ratio of Example 3. FIG.

FIG. 13 is a graph showing a load-compression deflection ratio of Example 4;

FIG. 14 is a graph showing a load-compression deflection ratio of Example 5;

FIG. 15 is a graph showing a load-compression deflection ratio of Example 6;

16 is a graph showing a load-compression deflection ratio of Example 7. FIG.

FIG. 17 is a graph showing the load-compression deflection ratio of Example 8.

FIG. 18 is a graph showing the load-compression deflection ratio of Example 9.

FIG. 19 is a graph showing a load-compression deflection ratio of Example 10.

20 is a graph showing load-compression deflection ratio of Example 11. FIG.

21 is a graph showing a load-compression deflection ratio of Comparative Example 1. FIG.

22 is a graph showing a load-compression deflection ratio of Comparative Example 2. FIG.

23 is a graph showing a load-compression deflection ratio of Comparative Example 3. FIG.

FIG. 24 is a graph showing a load-compression deflection ratio of Comparative Example 4.

FIG. 25 is a perspective view of the cushion member 110 and the base 104.

FIG. 26 is an explanatory view showing the first stage of the compression heating molding step of the cushion material 110.

FIG. 27 is an explanatory view showing a second stage of the compression heating molding step of the cushion material 110.

FIG. 28 is an explanatory diagram showing a third stage of the compression heating molding step of the cushion material 110.

29 is an explanatory diagram showing a step of attaching the cushion material 110 to the base 104. FIG.

30 (a), (b) and (c) are sectional views showing another embodiment of the spring structure resin molded product 30. FIG.

31 (a), (b), and (c) are cross-sectional views showing still another embodiment of the spring structure resin molded product 30. FIG.

32A and 32B are a back view and a perspective view of the molding die 622.

33 (a), (b) and (c) are cross-sectional views showing another embodiment of the spring structure resin molded product 30 or the linear member 31. FIG.

[Explanation of symbols]

10 Cushion Materials 10a, 10b Dimples 11 Front 12 Central 13 Sides 14 Rear 20 Extrusion Machine 21 Hopper 22 Molding Die 23 Pulling Machine 24 Pulling Roll 25 Bus 26 Winding Roll 30 Spring Structure Resin Molded Article 31 Wire 32, 33 sewing lines

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Maki Shirai             2-26-9, Nishigotanda, Shinagawa-ku, Tokyo             In Engineering Co., Ltd. (72) Inventor Yuichiro Nakamura             2-26-9, Nishigotanda, Shinagawa-ku, Tokyo             In Engineering Co., Ltd. F-term (reference) 3B096 AB07 BA02                 4L047 AA14 AA18 AA28 AB02 AB03                       AB09 BA09 BD01 CA19 CB01                       CC09

Claims (11)

[Claims] 1. A solid and / or hollow continuous filament and / or short filament random loop or curl consisting of a thermoplastic resin and having a predetermined bulk density formed by contact entanglement of adjacent filaments with each other. A three-dimensional structure having voids, wherein at least a predetermined linear region of a surface region is sewn with a sewing line of a thermoplastic resin or the like and compressed, so that at least two raised portions are formed on the front surface and the back surface, respectively. A cushion material made of a resin molded product having a spring structure, characterized in that 2. The spring structure resin molded article according to claim 1, wherein the thermoplastic resin is a mixture of a polyolefin resin and vinyl acetate resin, vinyl acetate vinyl acetate copolymer, or styrene butadiene styrene. Cushion material consisting of. 3. The mixing ratio of the vinyl acetate content of the polyolefin resin and the vinyl acetate resin or the vinyl acetate vinyl copolymer is
70-97% by weight: 3-30% by weight, preferably 80-
90% by weight: 10 to 20% by weight, the cushioning material comprising the resin molded product having a spring structure according to claim 2. 4. The mixing ratio of the polyolefin resin and styrene butadiene styrene is 50 to 97% by weight: 3 to 5
Cushion material comprising a resin molded product having a spring structure according to claim 2, wherein the cushion material is 0% by weight, preferably 70 to 90% by weight: 10 to 30% by weight. 5. The diameter of the continuous wire and / or the short wire is
0.3-3.0 mm, preferably 0.7-1.0 mm for solid filaments, 1.0 for hollow filaments.
To 3.0 mm, preferably 1.5 to 2.0 mm, the cushion material comprising the spring structure resin molded product according to any one of claims 1 to 4. 6. The bulk density of the spring structure resin molded product is 0.005 to 0.08 g / cm ³ , preferably 0.0.
08-0.07 g / cm ³ , especially 0.01-0.06
cushion material made of spring structure resin molded product according to any one of claims 1 to 5, characterized in that a g / cm ^3. 7. The porosity of the resin molded article having a spring structure is 91 to 99%, preferably 92 to 99%, particularly 9.
Cushion material consisting of a resin molded product having a spring structure according to any one of claims 1 to 6, which is 3 to 98%. 8. The spring structure resin molded product according to claim 1, wherein the mixing ratio of the solid filaments and the hollow filaments is solid: hollow = 0 to 50:50 to 100. Cushion material consisting of. 9. A spring structure resin molding according to claim 1, which is a seat for an automobile, a motorcycle, a bicycle, a train or an airplane, a saddle for riding, a chair, a sofa or a bed. Cushion material consisting of products. 10. A three-dimensional structure having a void of a predetermined bulk density, which is obtained by melting and extruding a thermoplastic resin into a plurality of filaments and extruding the filaments so that adjacent filaments of random loops of continuous filaments or curls adjoin each other. A body is molded, the peripheral edge of the spring structure resin molded product which is the three-dimensional structure is cut out in a U-shape or a V-shape, and the cut-out portion is sewn with a sewing line of thermoplastic resin or the like, A method for manufacturing a cushioning material composed of a resin molded product having a spring structure, characterized in that predetermined linear areas of the front surface and the back surface of the three-dimensional structure are sewn together with a sewn line of thermoplastic resin or the like. 11. A continuous and / or hollow continuous linear and / or short linear random loop or curl consisting of at least a thermoplastic resin is contact entangled and assembled on a female mold. A three-dimensional structure having voids of a predetermined bulk density is formed, and the female mold and / or the three-dimensional structure is heated under a temperature condition necessary for softening the three-dimensional structure, Then, the three-dimensional structure is clamped with, the spring characteristics are fixed by cooling, and the predetermined linear regions of the surface regions of the front and back faces of the three-dimensional structure are sewn with a sewn line of thermoplastic resin or the like. A method of manufacturing a cushion material made of a resin molded product having a spring structure, the method comprising: