JP2004358917A - Method of producing pad for sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce the fraction defective and the rate of repair of pads for sheets with an elastic nonwoven fabric integrated with the back by improving the manufacturing work properties in the production of the pads. <P>SOLUTION: When the pad 10 with the elastic nonwoven fabric 14 integrated with the back is produced by setting the nonwoven fabric 14 in a foaming mold 20 and foaming an injected foaming raw material 32, fitting pins 28 penetrating prescribed spots of the nonwoven fabric 14 to support the nonwoven fabric 14 are set in the mold 20, reinforcing sheets 16 are fitted to the parts penetrated by the pins 28 of the nonwoven fabric 14, and the nonwoven fabric 14 reinforced in this way is set in the mold 20. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a seat pad used for a vehicle or furniture seat.
[0002]
[Prior art]
Conventionally, for example, in the case of a cushion pad for an automobile seat, a backing material such as a felt or a coarse blanket is integrally laminated on the back surface of the pad in order to suppress breakage and generation of abnormal noise due to friction with a seat frame. There are many. Such a backing material is generally set on an upper mold via a mounting pin provided on an upper mold, and is foamed by injecting a foaming material into a lower mold so as to be laminated and integrated on the back surface of the pad body which is a foam. ing.
[0003]
As such a backing material, Patent Literature 1 listed below discloses a technique using a stretchable nonwoven fabric such as a thermoplastic polyurethane elastomer spunbonded nonwoven fabric in order to eliminate discomfort and discomfort during sitting and improve sitting comfort. Has been proposed.
[0004]
[Patent Document 1] Japanese Patent No. 30566605
[Problems to be solved by the invention]
The stretchable nonwoven fabric is very effective from the viewpoint of improving riding comfort, but on the other hand, at the time of manufacture, since the nonwoven fabric alone is too soft and has no waist, there are the following problems.
[0006]
That is, (1) When an operator sets the stretchable nonwoven fabric on the upper mold, when taking the stretchable nonwoven fabric from the storage place, a plurality of the stretchable nonwoven fabrics are taken at the same time and set as it is. (2) Since it is difficult to insert the stretchable nonwoven fabric into the mounting pins, the speed of the production line has recently been increased, and the foaming mold has been set at a very short time. (3) For this reason, it may not be set sufficiently and may come off from the mounting pin. (4) Also, after setting, the foaming mold comes off with the force of closing, and is subject to repair and failure.
[0007]
The present invention has been made in view of such a point, and significantly improves the manufacturing workability of a sheet pad in which an elastic nonwoven fabric is integrated on the back surface, and reduces the defective rate and the repair rate. It is another object of the present invention to provide a method for manufacturing a pad for a sheet, which can reduce the cost.
[0008]
[Means for Solving the Problems]
The method for producing a sheet pad of the present invention is such that the stretchable nonwoven fabric is set in a foaming mold, and a foaming material is injected into the foaming mold and foamed, so that the stretchable nonwoven fabric is integrated on the back surface. A method for manufacturing a pad for a sheet, comprising: providing a plurality of mounting pins for supporting a stretchable nonwoven fabric through a predetermined portion of the stretchable nonwoven fabric in the foam molding die; A reinforcing layer is provided in a portion penetrated by the above or reinforced by a curing treatment, and the reinforced stretchable nonwoven fabric is set in the foaming mold.
[0009]
The reinforcing layer can be provided, for example, by attaching a reinforcing sheet to a stretchable nonwoven fabric.
[0010]
In the manufacturing method of the present invention, the expected penetration position is reinforced by providing a reinforcing layer or performing a hardening treatment at the intended penetration position of the mounting pin in the stretchable nonwoven fabric, and inserting the mounting pin into the reinforced portion. Then, the stretchable nonwoven fabric is set in the foaming mold. As described above, since the partially reinforced stretchable nonwoven fabric is used to set the foaming mold, it is easy to handle, the burden on the operator is reduced, and mounting errors are reduced. The defective rate and the repair rate can be greatly reduced.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0012]
As shown in FIG. 3, the seat pad according to the present embodiment is a seat cushion pad 10 for an automobile seat, and includes a pad body 12 made of an elastic synthetic resin foam such as a flexible polyurethane foam. And a stretchable nonwoven fabric 14 integrally formed over substantially the entire back surface (lower surface) of the pad body 12.
[0013]
As the stretchable nonwoven fabric 14, a stretchable nonwoven fabric made of an elastic fiber and having a breaking elongation of 150% or more is preferable. More specifically, the elastic fiber made of polyurethane or rubber-based elastomer is used as a material, and is a nonwoven fabric manufactured by, for example, a spunbond method or a melt-blow method, which has a high elongation and a high recovery rate that are comparable to those of a flexible polyurethane foam. It is desirable to select and use a conductive nonwoven fabric, the elongation at break is preferably 150 to 600%, and the basis weight is preferably about 50 to 300 g / m ² . Examples of the stretchable nonwoven fabric having such properties include a thermoplastic polyurethane elastomer spunbonded nonwoven fabric (for example, “Espanione” (trade name), manufactured by Kanebo Co., Ltd.) and a melt-blown nonwoven fabric made of styrene / hydrogenated polyisoprene block copolymer. (For example, “Septon MB” (trade name), manufactured by Kuraray Co., Ltd.).
[0014]
As shown in FIG. 1, the foaming mold 20 used for manufacturing the seat cushion pad 10 is rotatable via a lower mold 22 opening upward and a hinge portion 24 arranged on one side of the lower mold 22. And an upper mold 26 provided to open and close the upper opening of the lower mold 22. Specifically, the lower mold 22 is a mold for molding the surface (upper surface) side of the pad, and has a concave portion corresponding thereto. The upper mold 26 is a mold for molding the back surface (lower surface) of the pad. By closing the concave portion, the upper mold 26 corresponds to a pad shape between the lower mold 22 and the inside of the contact surface (PL portion). A cavity, which is a foaming space, is formed.
[0015]
The upper die 26 is provided with a plurality of mounting pins 28 at predetermined locations for setting the elastic nonwoven fabric 14 on the inner surface thereof. As shown in FIG. 2, the mounting pin 28 is provided so as to protrude into the cavity from the inner surface of the upper mold 26, has a tapered tip, and pierces a predetermined portion of the elastic nonwoven fabric 14 to penetrate. Then, the elastic nonwoven fabric 14 is detachably engaged with the surface of the upper mold 26 in the cavity. The arrangement position and the number of the mounting pins 28 are not particularly limited as long as the stretchable nonwoven fabric 14 can be entirely supported on the inner surface of the upper mold 26. For example, in this embodiment, the mounting position and the number of the mounting pins 28 are different from those of the front end of the seat cushion pad 10. It is provided at each of two places on the left and right sides at the rear end (see FIGS. 1, 3, and 4).
[0016]
The reinforcing sheet 16 is attached to a portion of the elastic nonwoven fabric 14 through which the mounting pin 28 passes. The reinforcing sheet 16 is a sheet material having a size enough to surround the periphery of the mounting pin 28. If the sheet material has a lower elasticity than the elastic nonwoven fabric 14, for example, a non-stretchable material such as a coarse blanket or felt is used. Alternatively, paper or a resin sheet may be used in addition to a low-elastic cloth. Preferably, a coarse blanket having a low basis weight (a basis weight of 50 to 200 g / m ² ) is used. In addition, as a method of attaching the reinforcing sheet 16 to the elastic nonwoven fabric 14, in addition to sewing or using an adhesive, the reinforcing sheet 16 can be fixed with a stapler or a tag.
[0017]
When manufacturing the seat cushion pad 10 using the foaming mold 20, the elastic nonwoven fabric 14 reinforced by the reinforcing sheet 16 is set on the inner surface of the upper mold 26, as shown in FIG. 1. More specifically, the portion to which the reinforcing sheet 16 is attached is pressed against the mounting pin 28 of the upper die 26 to pierce the mounting pin 28 and penetrate the reinforcing sheet 16 together with the elastic nonwoven fabric 14 as shown in FIG. . In this case, the elastic nonwoven fabric 14 alone is hard to be attached because it is soft and has no waist, but can be attached stably because the reinforcing sheet 16 is overlapped on the penetrating portion.
[0018]
Next, as shown in FIG. 1, the foaming raw material 32 is injected into the concave portion of the lower mold 22 from the injection device 30, the upper mold 26 is closed, and the foam is hardened in the cavity. Thereafter, the upper mold 26 is opened and the mold is removed, whereby the seat cushion pad 10 is obtained.
[0019]
As shown in FIGS. 3 and 4, the obtained seat cushion pad 10 is obtained by integrally forming a stretchable nonwoven fabric 14 on the back surface, and the stretchable nonwoven fabric 14 expands even after the integrally formed foam material is impregnated. As a result, there is no discomfort or discomfort in the sitting comfort, and the stroke feeling and the resilience are excellent. Here, since the reinforcing sheet 16 is provided only partially on the periphery of the mounting pin 28, the characteristics of the elastic nonwoven fabric 14 are not impaired. Reference numeral 18 in FIGS. 3 and 4 indicates a trace of the mounting pin 28, that is, a hole formed by the mounting pin 28 during foam molding.
[0020]
According to the present embodiment described above, the reinforcing sheet 16 is attached to the elastic nonwoven fabric 14 at the position where the mounting pin 28 is to be penetrated, and the elastic nonwoven fabric 14 reinforced in this manner is attached via the mounting pin 28. Since the stretchable nonwoven fabric 14 is set on the upper mold 26, the handleability of the stretchable nonwoven fabric 14 is improved, and the burden on the operator is reduced, so that mounting errors can be reduced. Further, since the penetrating portion of the mounting pin 28 is reinforced by the reinforcing sheet 16, detachment after setting the elastic nonwoven fabric 14 is prevented, and the defective rate and the repair rate can be significantly reduced.
[0021]
In the above embodiment, the reinforcing sheet 16 is provided on the surface of the stretchable nonwoven fabric 14 on the pad body 12 side so that the reinforcing sheet 16 is not exposed to the outside in a product state. It can also be provided so as to be exposed to
[0022]
Further, in the above embodiment, in order to reinforce the penetrating portion of the mounting pin 28, a configuration in which the reinforcing sheet 16 is attached to the elastic nonwoven fabric 14 to form a reinforcing layer is employed. May be applied to the elastic nonwoven fabric 14 to form a coating film made of the synthetic resin. Instead of forming the reinforcing layer as described above, the reinforcing layer can be reinforced by a hardening treatment. As the curing treatment, for example, a method of impregnating a part of the elastic nonwoven fabric 14 with a synthetic resin solution by using a spray or the like and curing the same, a method of fusing a part of the elastic nonwoven fabric 14 by hot pressing and curing, and the like Is mentioned.
[0023]
【The invention's effect】
According to the method for manufacturing a sheet pad of the present invention, a reinforcing layer is provided at a position where a mounting pin is to be penetrated in a stretchable nonwoven fabric or a hardening treatment is performed to reinforce the planned penetrating position. Using a stretchable nonwoven fabric that has been set in a foaming mold, the burden on the operator is reduced, mounting errors are reduced, and the defect rate and repair rate due to the detachment of the stretchable nonwoven fabric are greatly reduced. It is possible to reduce the cost.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a foaming mold according to an embodiment of the present invention.
FIG. 2 is an enlarged view of a main part of FIG.
FIG. 3 is a sectional view of a seat cushion pad in the embodiment.
FIG. 4 is a bottom view of the seat cushion pad in the embodiment.
[Explanation of symbols]
10 Seat cushion pad 12 Pad body 14 Elastic non-woven fabric 16 Reinforcement sheet (reinforcement layer)
20 foam molding die 22 lower die 26 upper die 28 mounting pin

Claims (3)

A method for producing a sheet pad in which the stretchable nonwoven fabric is integrated on the back surface by setting the stretchable nonwoven fabric in the foaming mold and injecting a foaming material into the foaming mold to cause foaming,
Along with providing a plurality of mounting pins for supporting the stretchable nonwoven fabric through a predetermined portion of the stretchable nonwoven fabric in the foam molding die, a reinforcing layer is provided in a portion of the stretchable nonwoven fabric that is penetrated by the mounting pins, A method for manufacturing a sheet pad, comprising setting the reinforced stretchable nonwoven fabric in the foaming mold. The method for manufacturing a pad for a sheet according to claim 1, wherein the reinforcing layer is provided by attaching a reinforcing sheet to the elastic nonwoven fabric. A method for producing a sheet pad in which the stretchable nonwoven fabric is integrated on the back surface by setting the stretchable nonwoven fabric in the foaming mold and injecting a foaming material into the foaming mold to cause foaming,
A plurality of mounting pins that penetrate a predetermined portion of the elastic nonwoven fabric and support the elastic nonwoven fabric are provided in the foam molding die, and a portion of the elastic nonwoven fabric that is penetrated by the mounting pin is reinforced by a hardening process. And setting the reinforced stretchable nonwoven fabric in the foaming mold.

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