JP2005177197A - Pad for seat - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent abnormal sound due to scratch sound with a support frame in a pad for a seat. <P>SOLUTION: The pad 10 for the seat is composed of a pad body 12 composed of polyurethane foam and a reinforcing material 14 integrated on the back surface by the expansion molding of the polyurethane foam. The reinforcing material 14 is composed by laminating and integrating a textile layer 20 composed of a textile and a nonwoven fabric layer 22 composed of short fibers of 1-5 dtex by needle punching work, the fuzzing of a surface on the side of the nonwoven fabric layer 22 is 4 pieces/5cm or more, and it is integrated with the pad body 12 with the side of the nonwoven fabric layer 22 on the side of the pad body 12. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a seat pad used as a seat cushion material for a vehicle or the like.

  In general, a seat pad used as a seat cushion material for a vehicle or the like is made of a molded product of a soft polyurethane foam having a high cushioning property. A seat for a vehicle or the like is placed on a support frame. The pad surface is covered with an epidermis. In such a pad for a sheet, a reinforcing material such as a nonwoven fabric is integrated by foam molding of polyurethane foam in order to protect and reinforce the back surface of the pad body made of polyurethane foam from damage due to friction with the support frame. ing.

For example, the following Patent Document 1, basis weight 10 to 30 g / a thin dense layer of ^{m 2,} urethane foam molding reinforcement consisting of a nonwoven fabric formed by integrating the bulky layer in the coarse of basis weight 40 to 100 g / ^{m 2} A technique is disclosed in which the reinforcing material is integrated as a pad body side in contact with the polyurethane foam on the bulky layer side.

Patent Document 2 listed below uses a reinforcing material for foam molding which is made of a high-weight nonwoven fabric having a basis weight of 110 to 800 g / m ² and a fiber diameter of 1 to 16 d, and has a pressure-bonding layer on one surface side. Is disclosed in which the opposite surface of the pressure-bonding layer is integrated as the pad body side in contact with the polyurethane foam.

  In the techniques described in Patent Documents 1 and 2, the inner bulky layer is impregnated with polyurethane foam to increase the surface rigidity, and the outer dense layer clogs the air vent holes during foam molding with polyurethane foam. It plays a role of a filter to prevent the above.

On the other hand, in Patent Document 3 below, the layer in contact with the polyurethane foam is a dense nonwoven fabric having a basis weight of 20 to 100 g / m ² and a porosity of 87 to 91%, and the layer in contact with the coil spring or the like is 30 to 300 g / m ^2. And a pad for a sheet in which a polyurethane foam is foam-molded using a reinforcing material obtained by forming a bulky nonwoven fabric with a porosity of 90 to 94% and laminating and integrating them.

Further, the following Patent Document 4, a bulky nonwoven fabric layer of the porosity 90-94% and the upper and lower layers with basis weight 30 to 200 g / ^{m 2,} a basis weight 20 to 100 g / ^{m 2} in porosity from 87 to 91% of dense A sheet pad is disclosed in which polyurethane foam is foam-molded using a reinforcing material laminated and integrated with a nonwoven fabric layer as an intermediate layer.

In the technologies described in Patent Documents 3 and 4, the dense nonwoven fabric layer contributes to both the impregnation function and the blocking function during foaming of the polyurethane foam, and the bulky nonwoven fabric layer contributes to the urethane blocking property. The polyurethane foam is made so as not to come into direct contact with the coil spring. Therefore, it has the ability to prevent the seat pad from being lowered in rigidity and to prevent the generation of abnormal noise.
Japanese Utility Model Publication No. 62-26193 JP-A-2-258332 JP-A-6-171002 JP-A-6-171003

  The above conventional pad for a sheet uses a non-woven fabric as a reinforcing material, and the non-woven fabric is easily stretched due to its structure, so that there is a limit to the reinforcing effect on the back surface of the sheet pad. In addition, a reinforcing material formed by laminating two or more layers of nonwoven fabric is generally expensive, and the use of a cheaper reinforcing material is required to reduce the manufacturing cost of the sheet pad. On the other hand, if polyurethane penetrates the reinforcing material and leaches out to the surface during foam molding of the pad main body, abnormal noise is generated due to rubbing with the support frame, so this abnormal noise is reliably prevented. There is a need to.

  The present invention has been made in view of the above points, and is excellent in the effect of reinforcing the back surface of the pad while being low in cost, and can prevent the generation of abnormal noise due to scratching noise with the support frame. An object of the present invention is to provide a seat pad that can be used.

  The pad for a sheet of the present invention is a pad for a sheet comprising a pad main body made of polyurethane foam and a reinforcing material integrated on the back surface of the pad main body by foam molding of the polyurethane foam, and the reinforcing material is A woven fabric layer made of woven fabric and a non-woven fabric layer made of short fibers of 1 to 5 dtex are laminated and integrated by needle punching, and the fluffing on the surface of the nonwoven fabric layer side is 4/5 cm or more, Moreover, the said nonwoven fabric layer side is made into the said pad main body side, and is integrated with the said pad main body.

In the sheet pad of the present invention, it is preferable that the reinforcing material has 10 to 50 fluffs on the surface of the nonwoven fabric layer. Moreover, it is preferable that the fabric weight of a nonwoven fabric layer is 20-300 g / m < ² >, More preferably, it is 20-120 g / m < ² >. The reinforcing material preferably has an air permeability of 20 to 60 cm ³ / cm ² / s.

  In the case of the sheet pad of the present invention, the nonwoven fabric layer disposed on the pad body side during foam molding has a dense structure due to the fine denier of the short fibers, thus preventing the polyurethane foam from seeping out. Therefore, it is possible to eliminate the generation of abnormal noise due to the rubbing noise with the support frame. Further, since the reinforcing material is a layer having a lot of fluff on the nonwoven fabric layer side, the fluff enters the polyurethane foam, and high adhesive strength with the pad main body is obtained. Furthermore, according to the present invention, a high reinforcing effect on the back surface of the pad can be obtained by the fabric disposed on the support frame side, and the cost can be reduced as compared with the nonwoven fabric.

  Hereinafter, the pad for sheets concerning the embodiment of the present invention is explained in detail.

  FIG. 1 is a cross-sectional view of a reinforcing material in the embodiment, FIG. 2 is an enlarged cross-sectional view of a main part of a seat pad using the reinforcing material, and FIG. 3 is a cross-sectional view showing a state in which the seat pad is attached to a support frame. FIG.

  As shown in FIG. 3, the seat pad 10 of the present embodiment is a cushion pad used for a seat surface portion of an automobile, and includes a pad body 12 made of a flexible polyurethane foam and a reinforcing material laminated and integrated on the back surface thereof. 14 and disposed on a metal support frame 50.

  The reinforcing material 14 is set in advance in the mold when the pad 10 for the sheet is molded, and the polyurethane foam raw material is injected into the mold and foamed to be integrated with the back surface of the pad main body 12. It is provided over the entire contact portion with the support frame 50. The support frame 50 has a substantially rectangular shape corresponding to the lower surface portion of the seat pad 10, and extends in the left-right direction to receive the front receiving surface portion 52 that receives the lower surface of the front portion of the pad 10 and the rear end portion of the pad 10. The rod 54 includes a spring 56 that is stretched between the front receiving surface portion 52 and the rod 54 and elastically supports the seating portion of the pad 10.

  As shown in FIG. 1, the reinforcing material 14 used in this embodiment is a two-layered sheet in which a woven fabric layer 20 made of a woven fabric and a nonwoven fabric layer 22 made of a short fiber web are laminated and integrated by needle punching. It is a fiber structure. In FIG. 1, the woven fabric layer 20 and the non-woven fabric layer 22 are shown as being completely separated, but both layers 20 and 22 are actually needle punched so that the short fibers of the non-woven fabric layer 22 are actually entangled in the structure of the woven fabric. In many cases, a part of the short fiber penetrates through the fabric layer 20 and is exposed on the back surface side, and the present invention includes such a case.

As the woven fabric constituting the woven fabric layer 20, in order to enhance the reinforcing effect on the sheet pad, in particular, the wear strength with the support frame 50, a woven fabric including yarns composed of long fibers is preferable. A woven fabric made of polyolefin yarn is preferably used. The fabric weight is preferably ²⁰ to 100 g / m ² , and more preferably 40 to 80 g / m ² .

As the nonwoven fabric layer 22, a short fiber web made of short fibers of 1 to 5 dtex is used, more preferably a short fiber web of 1 to 3 dtex. By using such a short fiber web having a small fineness, the fiber structure in the nonwoven fabric layer 22 is densified, and the function of preventing the seepage of polyurethane can be enhanced. Here, the basis weight of the nonwoven fabric layer 22 is preferably ²⁰ to 300 g / m ² , more preferably 20 to 120 g / m ² , and still more preferably 30 to 100 g / m ² . If the basis weight of the nonwoven fabric 22 is less than 20 g / m ² , polyurethane may not be sufficiently prevented from seeping out. In addition, the kind of the short fiber which comprises the nonwoven fabric layer 22 is not specifically limited, For example, Polyolefin fibers, such as polyethylene and a polypropylene, Polyester fibers, such as a polyethylene terephthalate and a polybutylene terephthalate, Polyamides, such as polyamide 6 and the polyamide 66 System fibers and the like.

  As a method of laminating and integrating the woven fabric layer 20 and the non-woven fabric layer 22 described above, a short fiber web is placed on the woven fabric, and the short fibers are entangled with the constituent yarns of the woven fabric by needle punching from the short fiber web side. Can be integrated so as not to peel off. The conditions of the needle punch change accordingly because the peel strength between the woven fabric layer 20 and the nonwoven fabric layer 22 and the air permeability of the reinforcing material 14 to be obtained change, so that they are set appropriately according to the target peel strength and air permeability. Can do. In addition, you may heat-press with respect to the obtained reinforcing material 14 after a needle punch process, and this raises the density of the reinforcing material 14, especially the nonwoven fabric layer 22 part, and has the effect of preventing the seepage of polyurethane. Can be increased.

  The reinforcing material 14 thus obtained has a fluff on the surface on the nonwoven fabric layer 22 side of 4/5 cm or more, more preferably 6/5 cm or more, and further preferably 10-50 / 5 cm or more. It is. The evaluation method of fluff is the number of fibers having a length of 5 mm or more from the surface of the nonwoven fabric at the crease part by folding a sample (reinforcing material 14) having a width of 5 cm in half so that the nonwoven fabric layer 22 appears outside. (See paragraph [0024] of JP-A-2001-11767).

Further, air permeability of the reinforcing member 14 is preferably 20~60cm ³ / ^cm 2 / s, more preferably 30~40cm ³ / ^cm 2 / s. If the air permeability is less than 20 cm ³ / cm ² / s, there is a possibility that the air permeability required for the reinforcing material (gas venting function from the gas vent hole of the mold) may be insufficient, while 60 cm ³ / cm ^2. When it exceeds / s, there is a possibility that the function of preventing the seepage of polyurethane becomes insufficient.

  As shown in FIG. 2, the reinforcing member 14 is integrated with the pad body 12 with the nonwoven fabric layer 22 side as the pad body 12 side. That is, at the time of foam molding of the sheet pad 10, when the reinforcing material 14 is set in the mold, the nonwoven fabric layer 22 faces the polyurethane foam raw material side in the mold, and the fabric layer 20 faces the mold molding surface side. Place it toward the. And by injecting and foaming polyurethane foam raw material into this mold, the foamed polyurethane foam penetrates into the nonwoven fabric layer 22, but this nonwoven fabric layer 22 has a dense structure due to fine denierization. Therefore, the polyurethane foam can be reliably prevented from seeping out in the nonwoven fabric layer 22. Therefore, it is possible to eliminate the generation of abnormal noise due to the rubbing noise with the support frame 50. Further, since the nonwoven fabric layer 22 is a layer having a lot of fluff on the surface, the fluff enters the polyurethane foam at the time of foaming, and high adhesive strength with the pad main body 12 can be obtained.

  Further, the support frame 50 side is reinforced by the woven fabric layer 20 of the reinforcing material 14, and the woven fabric layer 20 is generally harder to stretch than the non-woven fabric, so that a high reinforcing effect is obtained. Further, excellent durability can be obtained by exhibiting high wear strength against friction with the support frame 50.

  Examples will be described below, but the present invention is not limited to such examples.

A polypropylene short fiber web was placed on a polypropylene fabric having a basis weight of 60 g / m ² , and both were laminated and integrated by needle punching to produce the reinforcing materials 14 of Examples 1 to 4 and Comparative Example 1. The fineness and basis weight of the short fiber web used, and the fluffing and air permeability of the obtained reinforcing material are as shown in Table 1 below.

  The fluff in Table 1 is the fluff on the surface of the nonwoven fabric layer 22 side, and the measuring method is as described above. The air permeability was measured according to JIS L1096 8.27.1 A method (Fragile method).

  In the mold, the reinforcing material 14 obtained above is arranged with the nonwoven fabric layer 22 facing the polyurethane foam raw material side in the mold and the fabric layer 20 facing the upper surface of the mold (upper cavity surface). According to a conventional method, a polyurethane foam raw material was injected into a mold and foam-molded to produce a sheet pad 10 in which a reinforcing material 14 was laminated and integrated on the back surface of the pad body 12.

  The prepared sheet pad was cut and the state of impregnation and leaching of the polyurethane foam was observed. The results are shown in Table 1. In the table, “◯” means that no oozing occurred, “Δ” means that oozing was slightly observed, and “X” means that oozing was recognized.

  In addition, the adhesive strength between the pad main body 12 and the reinforcing material 14 is set to a tensile speed of 200 mm / s per sample of thickness 10 mm × width 25 mm × length 150 mm (thickness is reinforcing material + urethane) using an Instron type tensile tester. Measured in minutes. The results are shown in Table 1.

In addition, the prepared seat pad was attached to the front seat of an automobile, and 10 panelists traveled at high speed to evaluate the presence or absence of scratching noise. The results are shown in Table 1. In the table, “◯” means that no scratching sound is present, “Δ” means that a slight scratching sound is recognized, and “X” means that a scratching sound is recognized.

It is sectional drawing of the reinforcing material in one Embodiment of this invention. It is a principal part expanded sectional view of the pad for sheets concerning the embodiment. It is sectional drawing which shows the state with which the pad for the sheet | seat was mounted | worn to the support frame.

Explanation of symbols

10 …… Sheet pad 12 …… Pad body 14 …… Reinforcing material 20 …… Fabric layer 22 …… Nonwoven fabric layer

Claims (4)

A pad for a sheet comprising a pad body made of polyurethane foam and a reinforcing material integrated by foam molding of the polyurethane foam on the back surface of the pad body,
The reinforcing material is formed by laminating and integrating a woven fabric layer made of a woven fabric and a non-woven fabric layer made of short fibers of 1 to 5 dtex by needle punching, and the surface of the nonwoven fabric layer has 4 fluffs / A pad for a sheet which is 5 cm or more and is integrated with the pad main body with the nonwoven fabric layer side as the pad main body side.   The pad for a sheet according to claim 1, wherein the reinforcing material has 10-50 fluffs on the non-woven fabric layer side surface. The basis weight of the nonwoven fabric layer is 20 to 300 g / ^{m 2,} also claim 1 or 2 sheets pad according permeability of the reinforcing material is characterized by a 20~60cm ³ / ^cm 2 / s . The sheet pad according to claim 3, wherein the basis weight of the nonwoven fabric layer is 20 to 120 g / m ² .

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