JP2005238675A - Pad for sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a pad for a sheet which is excellent in noise prevention effect. <P>SOLUTION: The pad 10 has a pad body 12 of a flexible foam and a reinforcing cloth 14 integrated with the back of the pad body by the foaming of the flexible foam. The reinforcing cloth 14 is made of a nonwoven fabric having a partial hot press bonding part 50 by embossing. The depths of the recesses 52 and 54 on the surface and back sides of the part 50 are different from each other. The surface on the side of the deep recess 52 is turned outside, and the surface on the side of the shallow recess 54 is arranged on the side of the flexible foam to be integrated with 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 a molded product of a flexible flexible foam such as a flexible polyurethane foam. Such a seat pad is configured as a seat by being assembled to a mounting steel material such as a spring, a frame, a pipe, etc., but abnormal noise is generated due to vibration between the pad and the mounting steel material during seating. Or there was a problem of damage. Therefore, in order to prevent the occurrence of such abnormal noise or to protect and strengthen from damage, a reinforcing fabric such as a nonwoven fabric as a backing material is integrally formed on the back surface of the pad body made of flexible foam by foam molding of the flexible foam. It has been made.

For example, in the following Patent Document 1, the layer in contact with urethane 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 a coil spring or the like is 30 to 300 g / m ^2. And a cushioning material for a formable polyurethane seat made of a reinforcing base fabric for urethane foam molding in which a bulky nonwoven fabric having a porosity of 90 to 94% is laminated and integrated.

Further, the following Patent Document 2, 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 vehicle seat made of a urethane foam molding reinforcing material laminated and integrated with a nonwoven fabric layer as an intermediate layer is disclosed.

Further, in Patent Document 3 below, a nonwoven fabric composed of crimped continuous fibers having a fineness of 0.5 to 10 denier and partially thermocompression bonded, having a basis weight of 50 to 200 g / m ² and a thickness of 0.5 to 2.0 mm. There is disclosed a foam base material for foam molding characterized by having the following.
JP-A-6-171002 JP-A-6-171003 JP 2000-62061 A

  As described in Patent Documents 1 and 2 above, as this type of reinforcing cloth, a nonwoven fabric that has been entangled with a needle punch is often used. Holes remain, which can cause oozing of the flexible foam. On the other hand, in the said patent document 3, the nonwoven fabric used for this kind of reinforcement cloth is manufactured by carrying out partial thermocompression bonding of the crimped continuous fiber web with a hot embossing roll. In this way, when non-woven fabrics are manufactured by partial thermocompression bonding by embossing and needle punching is not performed, needle holes do not remain in the reinforcing fabric, so it is easy to ensure high barrier properties of flexible foam and to prevent oozing .

  An object of this invention is to provide the pad for sheets which is more excellent in the noise prevention effect compared with the past, when using the nonwoven fabric provided with the partial thermocompression bonding part by such embossing as a reinforcement cloth.

  The pad for a sheet according to the present invention is a pad for a sheet comprising a pad main body made of a flexible foam and a reinforcing cloth integrated by foam molding of the flexible foam on the back surface of the pad main body. The cloth is made of a non-woven fabric provided with a partial thermocompression bonding part by embossing, and the depths of the front and back sides of the partial thermocompression bonding part are different, and the deep side faces outward and is integrated with the pad body. It is characterized by that.

  In the sheet pad of the present invention, the partial thermocompression bonding part may be provided in a lattice point shape by embossing.

  In the sheet pad of the present invention, the nonwoven fabric with different depths on the front and back sides of the partial thermocompression bonding part is used as a reinforcing cloth, the surface on the shallow side is the soft foam side, and the surface on the deep side is attached to a frame or the like It is integrated with the pad body on the steel side. Therefore, even if the flexible foam oozes out from the shallow concave part side beyond the thermocompression bonding part, since the deep concave part is secured on the outer side, the oozed flexible foam is attached to the mounting steel material. It is hard to touch and has an excellent noise prevention effect. Moreover, although this thermocompression bonding part is hardened | cured when a soft foam impregnates, since the deep recessed part is ensured on the outer side, it is excellent also in the soft feeling in a contact surface with an attachment steel material. Furthermore, since such a deep recess is ensured on the contact surface side with the mounting steel material, the contact area with the mounting steel material can be reduced to reduce the frictional resistance. Excellent.

  In the present invention, it is only necessary that the depths on both the front and back sides of the thermocompression bonding portion are different, and this includes a configuration in which only one surface of the thermocompression bonding portion has a recess and the other surface has no recess, In that case, the surface on the side having the recesses becomes the surface on the deep side of the thermocompression bonding portion described above. However, if the surface to be integrated with the pad body is shallow but has a recess as described above, the anchoring effect is exhibited by integrating so that the flexible foam enters the recess, and the reinforcing cloth And the pad body can be integrated more effectively.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  1 is a perspective view of a pad 10 for a sheet according to an embodiment of the present invention, FIG. 2 is a cross-sectional view of the pad 10, FIG. 3 is an enlarged cross-sectional view of the main part of the pad 10, and FIG. 5 is an enlarged sectional view of the reinforcing cloth 14, FIG. 5 is a development view of the reinforcing cloth 14, and FIGS. 6 and 7 are perspective views after the sewing.

  As shown in FIG. 1, this seat pad 10 is a back pad used for a backrest portion of a front seat of an automobile, for example, and includes a pad main body 12 made of a flexible polyurethane foam and a reinforcing layer laminated and integrated on the back surface thereof. It consists of cloth 14 and is assembled to a mounting steel material (not shown) such as a frame.

  The pad main body 12 has an inward flange-like overhang for frame mounting integrally provided on three sides of the pad main body portion 16 constituting the backrest and the upper side and the left and right sides on the back side. It consists of the part 18, and has comprised the outline bag shape as a whole. A through hole 19 for mounting a headrest (not shown) is provided on the upper surface of the pad main body 12.

  The reinforcing cloth 14 is sewn in a bag shape as shown in FIG. 6, and is integrally formed by foaming polyurethane foam so as to cover the back surface of the pad main body portion 16 and the inner side surface of the overhang portion 18 as shown in FIG. It has become.

  In the present embodiment, a nonwoven fabric provided with innumerable partial thermocompression bonding portions 50 in a lattice point shape by embossing is used as the base fabric constituting the reinforcing fabric 14. Here, the lattice point shape means a state in which the partial thermocompression bonding portions 50 are arranged at the intersections of the vertical and horizontal lattices, and the lattice is not limited to the orthogonal lattice, and is a lattice shape that intersects at an acute angle like a staggered lattice. But you can.

As shown in FIG. 4, the non-woven fabric constituting the reinforcing fabric 14 has different depths D <b> 1 and D <b> 2 of the concave portions 52 and 54 on both the front and back sides of the partial thermocompression bonding portion 50. That is, the concave portions 52 and 54 are provided on the front and back sides of the partial thermocompression bonding portion 50, and the concave portions 52 and 54 have different depths, and the depth D1 of the upper concave portion 52 is the depth of the lower concave portion 54 in FIG. It is set deeper than D2. The ratio of these depths D1 and D2 is preferably such that D1 is at least twice (more preferably 2 to 4 times) D2. In addition, although the area per thermocompression bonding part 50 is not specifically limited, It is preferable that it is 0.1-5 mm < ² >. Moreover, it is preferable that the minimum space | interval of the thermocompression bonding part 50 is about 1-5 mm.

Moreover, it is preferable that this nonwoven fabric is a long fiber nonwoven fabric which consists of a long fiber, and, thereby, it is excellent in abrasion resistance and intensity | strength. Moreover, it is preferable to use a crimped long fiber as the long fiber, whereby a soft texture can be obtained and the conformability to the mold can be improved. Furthermore, the cross-sectional shape of the fiber is preferably a flat cross-sectional shape rather than a round cross-section, and this can reduce the air permeability and increase the polyurethane foam seepage prevention effect. In addition, it is preferable that the fabric weight of a nonwoven fabric is 50-200 g / m < ² >, More preferably, it is 80-120 g / m < ² >. Moreover, it is preferable that the thickness of a nonwoven fabric is 0.5-2.0 mm, More preferably, it is 0.6-1.2 mm.

  Such a nonwoven fabric having the thermocompression bonding part 50 can be manufactured by embossing a nonwoven fabric obtained by a known nonwoven fabric manufacturing method such as a spunbond method. More specifically, a crimped continuous fiber web made of polypropylene or the like can be produced by passing between thermocompression-bonding rolls made of embossing rolls having convex portions arranged on the surface in lattice points. Thus, since it is manufactured by partial thermocompression bonding by embossing and does not have a needle punch, there is no needle hole, and therefore, the polyurethane foam exudation preventing effect is excellent.

  The reinforcing cloth 14 is formed by cutting the nonwoven fabric provided with the thermocompression bonding part 50 into a base cloth shape shown in FIG. The base cloth shape includes a substantially trapezoidal cloth main body portion 20 integrated with the back surface of the pad main body portion 16 and extending portions 18 a and 18 a on both side portions of the pad main body 12. The cloth side surface portion 22 integrated with the inner side surface of the cloth, the substantially rectangular cloth upper surface portion 24 integrally extending from the upper side of the cloth main body portion 20, and the pad main body extending integrally from the cloth upper surface portion 24. 12 and a substantially rectangular cloth rear surface portion 26 which is integrated with the inner surface of the overhang portion 18b in the upper side portion. The cloth upper surface portion 24 is provided with a through hole 36 for a headrest at a position relative to the through hole 19 of the pad main body 12.

  On the left and right sides of the cloth upper surface portion 24 and the left and right sides of the fabric rear surface portion 26, sewing margins 24a and 26a are provided, respectively. As shown in the drawing, the seam allowance 24a of the cloth upper surface portion 24 is formed to protrude outward by a predetermined dimension with respect to the seam allowance 26a of the fabric rear surface portion 26 via a step portion 28. Further, a seam allowance 22a is formed on the upper side of the cloth side surface portion 22 facing the seam allowance 24a of the fabric upper surface portion 24, and a seam allowance 22b is formed on the side of the fabric side surface portion 22 facing the seam allowance 26a of the fabric rear surface portion 26. ing. A V-shaped cutout 30 is provided at the boundary between the seams 22a and 22b so that the seams 22a and 22b can be easily laid after sewing. Furthermore, in order to make it easy to follow the back surface shape of the pad main body 12 at the lower side of the cloth side surface portion 22, a notch 32 having a predetermined length is provided, and a three-dimensional shape is produced using the notch 32 portion. A V-shaped notch 34 is provided as a mark for sewing. Further, a V-shaped notch 52 is provided in the vicinity of the left and right corners 26 c at the extended end 26 b of the cloth rear surface part 26, and the notch 52 is formed between the cloth side surface part 22 and the cloth rear surface part 26. When the opposing sides are stitched together, it becomes a mark when the seam allowances 22b and 26a of the two are overlapped.

  When the reinforcing fabric 14 is sewed using this base fabric, the above-described nonwoven fabric is sewn so that the surface having the deep concave portion 52 is inside the bag shape. Specifically, in FIG. 5, the deep concave portion 52 on the back surface side and the shallow concave portion 54 on the front surface side face each other, and first, the opposing sides 22 a and 24 a of the cloth side surface portion 22 and the cloth upper surface portion 24 are arranged. , And stitch together so that each side is parallel to each other. At that time, by sewing 38 with the seam allowance 22a of the cloth side surface portion 22 facing up and the seam allowance 24a of the cloth upper surface portion 24, as shown in FIG. 7, the seam allowance 22a of the cloth side surface portion comes out outside the bag shape. . Next, the opposing sides 22b and 26a of the cloth side face portion 22 and the cloth rear face portion 26 are stitched together. At that time, by sewing 40 with the seam allowance 22b of the cloth side face portion 22 facing up and the seam allowance 26a of the cloth rear face part 26, as shown in FIG. 7, the seam allowance 22b of the cloth side face portion comes out outside the bag shape. . Thereafter, the two fabric portions 32a and 32b cut by the cut 32 are overlapped to perform sewing 42 (see FIG. 6). The sewing 42 can also be performed prior to the sewing 38, 40. Further, it is preferable that the reverse stitching is performed once or more at the start point and the end point of each sewing 38, 40, 42.

  The reinforcing cloth 14 thus sewn in a bag shape is mounted in a foam molding die (not shown), and the foam main body is injected into the mold to be foam-filled. The sheet pad 10 shown in FIGS. At that time, as described above, the reinforcing cloth 14 is formed so that the surface on the deep concave portion 52 side is disposed on the inner side of the bag shape, so that the pad on the surface on the shallow concave portion 54 side as shown in FIG. The polyurethane foam of the main body 12 is bonded and integrated, and the surface on the deep concave portion 52 side faces outward and becomes a contact side with a mounting steel material such as a frame.

  According to this embodiment, regarding the thermocompression bonding part 50 of the nonwoven fabric constituting the reinforcing cloth 14, the pad main body 12 has a surface on the shallow concave portion 54 side as a polyurethane foam side and a surface on the deep concave portion 52 side as an attachment steel material side such as a frame. It is integrated with. Therefore, even if the polyurethane foam oozes out beyond the thermocompression bonding part 50 during foam molding, the deep polyurethane 52 is secured on the outside, so the oozed polyurethane foam is attached to the mounting steel material. It is hard to come into contact with and has excellent noise prevention effect.

  Further, the thermocompression bonding part 50 is cured by being impregnated with polyurethane foam, but there is a deep recess 52 on the outside thereof, so that a large distance from the cured thermocompression bonding part 50 to the mounting steel material can be secured. Excellent softness on the contact surface with steel.

  Further, since the deep concave portion 52 is secured on the contact surface side with the mounting steel material, the contact area with the mounting steel material can be reduced and the frictional resistance can be reduced. Excellent.

  Moreover, since it comprised so that the shallow recessed part 54 might be provided in the surface by the side of the pad main body 12 while ensuring the deep recessed part 52 in the surface by the side of an attachment steel material, it mentioned above, without enlarging the thickness of the reinforcement cloth 14 whole. The effect on the mounting steel material side due to the deep recess 52 can be exhibited, and the adhesive strength between the pad body 12 and the reinforcing cloth 14 can be increased by the polyurethane foam entering the recess 54 on the pad body 12 side. .

  Furthermore, according to the present embodiment, by sewing the reinforcing cloth 14 as described above, at the time of foam molding, the seam allowance 22a of the cloth portion located on the upstream side in the flow direction of the foaming stock solution in each of the sewing portions 38 and 40. 22b are arranged on the foaming stock solution side, and seam allowances 24a and 26a of the cloth portion located on the downstream side in the flow direction are arranged on the mold side, and the foaming stock solution is filled in this state. Therefore, at the time of foam filling, the flow of the foamed stock solution is not hindered by the sewing allowances 22a and 22b of the sewing portions 38 and 40 of the reinforcing cloth 14, and thus the moldability can be ensured.

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

Non-woven fabric obtained by passing between crimped long fiber webs made of polypropylene and between thermocompression rolls made of embossing rolls having convex portions arranged in a lattice pattern on the surface ("ELTAS Limp PC8100" manufactured by Asahi Kasei) , Basis weight = 100 g / m ² , thickness = 0.8 mm) was used as the above-described reinforcing cloth 14 to produce a sheet pad 10 (Example). This non-woven fabric has different depths of the front and back recesses 52 and 54 by the thermocompression bonding part 50 as shown in FIG. 4 (D1 = 0.6 mm, D2 = 0.2 mm), and is deep as shown in FIG. The pad main body 12 was integrated with the recess 52 facing outward.

  Further, as a comparative example, the reinforcing cloth 14 is integrated with the pad main body 12 so that the arrangement of the recesses 52 and 54 on the front and back sides by the thermocompression bonding part 50 is opposite to that of the above embodiment, that is, the deep recess 52 is on the polyurethane foam side. A sheet pad was prepared.

  The obtained 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 seat pad of the example showed no abnormal noise. In contrast, slight noise was observed in the sheet pad of the comparative example.

It is a perspective view of the pad for sheets concerning one embodiment of the present invention. It is the II-II sectional view taken on the line of FIG. It is a principal part expanded sectional view of this pad. It is a partial expanded sectional view of the reinforcement cloth used for this pad for sheets. It is an expanded view of this reinforcement cloth. It is a perspective view after sewing of this reinforcement cloth. It is a principal part expansion perspective view of this reinforcement cloth.

Explanation of symbols

10 …… Sheet pad 12 …… Pad body 14 …… Reinforcing cloth 50 …… Partial thermocompression bonding part 52 …… Deep recess 54 …… Shallow recess

Claims (2)

A pad for a sheet comprising a pad body made of a flexible foam and a reinforcing cloth integrated by foam molding of the flexible foam on the back surface of the pad body,
The reinforcing cloth is made of a non-woven fabric having a partial thermocompression bonding portion by embossing, and the depths of both sides of the partial thermocompression bonding portion are different, and the deep side faces outward and is integrated with the pad main body. Sheet pad characterized by being made into a product.   The sheet pad according to claim 1, wherein the partial thermocompression bonding portion is provided in a lattice point shape by embossing.

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