JP2006034730A - Pad for seat - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent occurrence of abnormal noise caused by abrasion sound with a support frame in a pad for a seat. <P>SOLUTION: The pad for the seat is provided with: a pad body 12 consisting of a polyurethane foam; and a reinforcing material 14 integrated by foaming molding of the polyurethane foam on its rear surface. The reinforcing material 14 consists of a nonwoven fabric to which a foam-like rein binder 38 is applied from one side face. The nonwoven fabric has a double layer structure having a resin-impregnated layer 20 which is impregnated with the resin binder on the side of the one side face and having a non-impregnated layer 22 which is not impregnated with the resin binder on the side of the other face. The reinforcing material 14 is integrated with the pad body with the side of the resin-impregnated layer 20 as the side of the pad body 12. <P>COPYRIGHT: (C)2006,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, in the following Patent Document 1, 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 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 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 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.
JP-A-6-171002 JP-A-6-171003

  In the technologies described in these patent documents, the dense nonwoven fabric layer contributes to both the impregnation function and the blocking function at the time of foam molding of the polyurethane foam, and the bulky nonwoven fabric layer contributes to the urethane blocking property and the polyurethane foam is It is designed not to come into direct contact with the coil spring. Therefore, although it is excellent in the rigidity reduction prevention and abnormal noise prevention ability of the pad for the sheet, since it is formed by laminating and integrating a plurality of non-woven fabrics, the reinforcing material tends to have a high basis weight, in terms of cost and weight Further improvement is required.

  The present invention has been made in view of the above points, and can provide a seat pad that can prevent the generation of abnormal noise due to scratching noise with the support frame, and is reduced in weight at low cost. The purpose is to provide.

  The seat pad of the present invention is a seat pad 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. Is a non-impregnated layer having a resin-impregnated layer impregnated with the resin binder on one side and a non-impregnated layer not impregnated with the resin binder on the other side. It is a nonwoven fabric having a two-layer structure having

  In this case, it is preferable that the reinforcing material is formed by applying a foamed resin binder to the nonwoven fabric from one surface thereof. Moreover, it is preferable that the said reinforcing material is integrated with the said pad main body by making the said resin impregnation layer side into the said pad main body side.

  According to the present invention, the use of a reinforcing material having a resin-impregnated layer on one side of the nonwoven fabric and a non-impregnated layer on the other side prevents the polyurethane foam from seeping out with the resin-impregnated layer. Thus, it is possible to prevent the generation of abnormal noise due to the rubbing noise with the support frame. In addition, because this reinforcing material is obtained by applying a resin binder from one side, it is easier to reduce the weight of the reinforcing material and reduce the weight compared to the case where multiple nonwoven fabrics are laminated and integrated. , Facilitating cost reduction.

  Further, by integrating the reinforcing material with the pad main body with the resin impregnated layer side as the pad main body side, it is possible to prevent the polyurethane foam from seeping out by the dense resin impregnated layer at the time of foam molding. Further, since the soft non-impregnated layer with many fluffs comes into contact with the support frame, it is possible to eliminate the generation of abnormal noise due to friction with the support frame.

  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 where 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 seat cushion pad used for a seat surface portion of an automobile, and is a pad body 12 made of a flexible polyurethane foam and a reinforcement integrated and laminated on the back surface thereof. The material 14 is arranged 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. The support frame is not limited to such a spring receiving type, but may be a type that receives the entire lower surface of the pad with a plate-like rigid body without a spring.

  The reinforcing material 14 has a resin impregnated layer 20 impregnated with a resin binder on one side by applying a resin binder from one side to a nonwoven fabric having a single layer structure, and the opposite side is impregnated with a resin binder. It has a two-layer structure with a non-impregnated layer 22 that is not. Such a reinforcing material 14 is obtained by applying the resin binder from one side of the nonwoven fabric so that the resin binder does not penetrate the entire thickness direction of the nonwoven fabric. For that purpose, it is preferable to apply a foam-like resin binder to one side of the nonwoven fabric.

  More specifically, the reinforcing material 14 can be produced by a process as shown in FIG. First, the short fiber which comprises a nonwoven fabric is carded, the thin sheet-like web 30 is produced, this is laminated | stacked, and the laminated web 32 is produced. The laminated web 32 is stretched by a stretcher (drafter) 34 to adjust the weight to obtain a nonwoven fabric 36 having a predetermined basis weight. The nonwoven fabric 36 is coated with a foamed resin binder 38 from the upper surface thereof using a pressure head 40. At the time of coating, the coating amount is adjusted so that the foam-like resin binder 38 does not penetrate the entire thickness direction of the nonwoven fabric 36. The foamed resin binder 38 can be prepared by stirring the emulsion of the resin binder with a mixer or the like, and an activator for improving foamability can be added as necessary. Thus, after apply | coating the foam-like resin binder 38, it puts on a net | network, puts into a dryer, and dries, but the heating roll is not used in that case. Thereby, the reinforcing material 14 having the two-layer structure described above is obtained.

  In the example of FIG. 4, the nonwoven fabric is produced by the card method. However, the present invention is not limited to this, and other known non-woven fabric production methods such as other dry methods such as air-lay method, spunbond method, and wet method are available. The method can be used. Examples of the fiber constituting the nonwoven fabric include polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyamides such as polyamide 6 and polyamide 66, and polyolefins such as polyethylene and polypropylene. In addition, as the resin binder, various known resin binders used as a nonwoven fabric binder (binder) can be used. For example, a resin made of an emulsion such as an acrylic resin, a urethane resin, or a vinyl acetate resin. A binder is mentioned.

The basis weight of the reinforcing material 14 is not particularly limited, but is preferably 60 to 140 g / m ² . Moreover, it is preferable to apply | coat so that the adhesion amount of a resin binder may be 5-60 g / m < ² > in conversion of solid content, It is preferable that it is 5-60 weight% as a ratio for the reinforcement material 14 whole, More preferably, it is 5 to 30% by weight.

  As shown in FIG. 2, the reinforcing member 14 is integrated with the pad body 12 with the resin impregnated layer 20 side as the pad body 12 side and the non-impregnated layer 22 side as the support frame 50 side. That is, when the reinforcing material 14 is set in the mold during foam molding of the sheet pad 10, the resin-impregnated layer 20 faces the polyurethane foam raw material side in the mold, and the non-impregnated layer 22 is molded in the mold. Place it facing the surface.

  Then, by injecting the polyurethane foam raw material into the mold and foaming, the foamed polyurethane foam penetrates into the resin impregnated layer 20 and the dense resin impregnated layer 20 blocks outflow of the polyurethane foam. The Further, in this case, even if the resin impregnated layer 20 slightly oozes out, the non-impregnated layer 22 having a lot of fluff disposed on the outside can prevent the polyurethane foam from contacting the support frame 50, thereby supporting the support. It is possible to eliminate the generation of abnormal noise due to the rubbing sound with the frame 50. In addition, since the non-impregnated layer 22 is softer than the resin-impregnated layer 20, it is possible to eliminate any abnormal noise caused by friction between the reinforcing member 14 and the support frame 50.

  Further, since the reinforcing material 14 is the resin-impregnated layer 20 impregnated with the resin binder only on one side, the one side is efficiently densified while suppressing an increase in the weight of the entire reinforcing material as much as possible. can do. That is, compared with the case where the resin binder is impregnated in the entire thickness direction of the nonwoven fabric, the one side can be densified (densified) while the same amount of the resin binder is adhered. For this reason, the densified resin impregnated layer 20 can enhance the blocking effect of the polyurethane foam at the time of foam molding while suppressing an increase in weight and amount of raw material used.

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

In accordance with the reinforcing material production process shown in FIG. 4, a non-woven fabric having a basis weight of 85 g / m ² is produced using 1.7 dtex polyester short fibers, and a foam-like resin binder is applied to one side of the non-woven fabric using a pressure head. And it apply | coated to the single side | surface of a nonwoven fabric so that adhesion amount might be 10 g / m < ² > in conversion of solid content. Here, as the resin binder, an acrylic emulsion containing an ethylene-vinyl acetate copolymer was used as a subcomponent for imparting flexibility, and the resultant was stirred with a mixer to form a foam. And after application | coating, the reinforcing material was obtained by drying with a dryer.

  The obtained reinforcing material is rigid on one side (resin-impregnated layer) applied, and the opposite side (non-impregnated layer) is not impregnated with a resin binder and has soft and moderate fuzz. there were.

  Using this reinforcing material, the resin-impregnated layer faces the polyurethane foam raw material side in the mold and the non-impregnated layer faces the upper surface of the mold (the upper cavity surface). It was injected into a mold and foamed to produce a sheet pad in which a reinforcing material was laminated and integrated on the back surface of the pad main body.

  Further, as Comparative Example 1, a non-impregnated nonwoven fabric was used as a reinforcing material, and a pad for a sheet was prepared in the same manner as in the above example. Further, as Comparative Example 2, the same amount of resin binder as in the example was applied without foaming to prepare a reinforcing material, and the resting pad was used in the same manner as in the above example using this reinforcing material. Was made. In the reinforcing material of Comparative Example 2, the resin binder was impregnated throughout the thickness direction of the nonwoven fabric.

  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. In Comparative Example 1, the generation of scratching noise was large. The generation of scratching noise was slightly observed, whereas no abnormal noise was generated in the examples.

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. It is process schematic which shows an example of the production process of the reinforcing material in embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Sheet pad 12 ... Pad body 14 ... Reinforcement material 20 ... Resin impregnated layer 22 ... Non-impregnated layer 36 ... Nonwoven fabric 38 ... Foam-like resin binder

Claims (3)

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 a non-woven fabric provided with a resin binder from one side, has a resin-impregnated layer impregnated with the resin binder on one side, and is not impregnated with the resin binder on the other side A sheet pad, which is a non-impregnated two-layer nonwoven fabric.   The sheet pad according to claim 1, wherein the reinforcing material is formed by applying a foamed resin binder to one side of the nonwoven fabric. The pad for a sheet according to claim 1 or 2, wherein the reinforcing material is integrated with the pad main body with the resin impregnated layer side as the pad main body side.

Images