JP2006205658A - Composite molded base fabric and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a sheet pad with an embedded foam block without increasing the number of members to be fitted to a molding tool. <P>SOLUTION: The composite molding base fabric 10 for a sheet pad is formed of a nonwoven fabric and fitted to the inner surface of the molding tool 46, and made into a monolithic sheet pad by supplying a foaming stock solution composition for forming a soft polyurethane foam, and expansion-curing it inside the molding tool 46. The cut base fabric is a composite molding base fabric 10 for the sheet pad having a foam block 21 with higher hardness than the soft polyurethane foam, fitted to a prescribed position. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a composite molded base fabric that is integrated into a seat pad together with foaming and curing of a foamed stock solution composition that is attached to a mold to form a polyurethane foam in the manufacture of a seat pad used in a vehicle seat. And a manufacturing method thereof.

  As a pad used for a vehicle seat, a soft polyurethane foam that is usually molded is used. The flexible polyurethane foam is mainly used for various insert fittings for mounting on seats, hook-and-loop fasteners for attaching the skin material of seats, and prevention of abnormal noise caused by sliding between pads and mounting brackets. A foaming stock composition for forming a flexible polyurethane foam is supplied to a molding cavity in a state in which a non-woven fabric molding base fabric cut into a predetermined shape is mounted on a molding die, and foamed and cured in the molding die. It is manufactured by integrating these members.

Many seat pads made of flexible polyurethane foam have a seating surface part and convex side parts formed on both sides thereof, and the side part and the seating surface part are made of soft polyurethane foam having different hardness. The forming technique is known (for example, Patent Document 1).
JP 2004-174762 A

  However, there is a case where it is desired to partially increase the hardness of only a part of the side portion of the seat pad, and the method of Patent Document 1 cannot meet such a request. As a technique for partially increasing the hardness of a part of the side portion of the seat pad, the side portion needs a small member having a higher hardness than that of the flexible polyurethane foam, in particular, a foam block having a predetermined shape considering light weight. A method of improving the performance by embedding in a part is considered. For the production of a sheet pad having such a structure, the foam block is mounted as a constituent member together with a molding base fabric and the like on a molding die, and a foaming stock solution composition A method is generally used in which a product is supplied and foam-cured to form a pad for a sheet.

  The sheet pad manufacturing process includes a member mounting process in which the above-described various members are mounted in a state where the mold is opened, an injection process in which a foaming stock solution composition for forming a flexible polyurethane foam is injected, and the mold is closed and foam-cured. A recycle-type production line in which a molding process, a demolding process for opening a mold and taking out a sheet pad as a molded product, a preparatory process for cleaning the inside of the mold and applying a release agent are continuously performed An injection step is provided adjacent to the member mounting step, and the molding die is configured to move on the line at a constant speed. Therefore, the time for the member mounting process is limited, and if the number of members to be mounted on the molding die is increased, the problem of insufficient mounting time occurs. It is possible to widen the interval between the member mounting process and the injection fixing and to set the line speed slower in order to secure the mounting time of the member to the mold that moves at a constant line speed. This is not preferable because it requires a change and is expensive, and the manufacturing cycle time of the sheet pad becomes long, and the manufacturing cost of the sheet pad increases as a whole.

  The present invention provides a composite molding base fabric used for manufacturing a sheet pad for manufacturing a sheet pad in which a foam block is embedded without increasing the number of members to be mounted on a molding die, and a method for manufacturing the same. It is intended to do.

The present invention relates to a seat pad which is made of a nonwoven fabric, is attached to the inner surface of a molding die, is supplied with a foaming stock solution composition that forms a flexible polyurethane foam, and is foam-cured and cured in the molding die to form an integrated sheet pad Composite molded base fabric for
The foam block having a higher hardness than that of the flexible polyurethane foam is mounted in at least one place.

  By using the composite molding base fabric having such a configuration, a pad for a sheet can be manufactured without increasing the number of members attached to the molding die. As a result, it is possible to manufacture a sheet pad having an increased number of members without causing problems such as changes in manufacturing facilities and an increase in manufacturing cycle time.

  In addition, when the foam block is mounted on a cut base fabric, for example, when the foam block is locked to a locking pin formed on the mold, particularly the upper mold, the foam block is moved by the movement of the mold. Is eliminated, and the foaming stock composition is supplied in this state, thereby causing a problem that defective products are generated.

  The composite molded base fabric is preferably one in which the foam block is accommodated in a pocket formed by sewing a pocket forming base fabric.

  The composite molded base fabric having such a configuration can be easily manufactured at low cost.

Another invention is for a seat pad comprising a non-woven fabric and integrated with foam curing of a foam stock solution composition that is attached to the inner surface of a mold and forms a flexible polyurethane foam fed into the mold. A method for producing a composite molded base fabric, comprising:
A cutting process for cutting a raw fabric into a cut base fabric, a pocket forming step for forming a pocket in at least one location on the cut base fabric, and a foam block having higher hardness than the flexible polyurethane foam in the pocket And a foam block mounting step of sealing the pocket to form a composite molded base fabric.

  According to such a manufacturing method, the foam block is fixed to the cutting base fabric in advance, and the number of members to be attached to the mold is reduced in the manufacture of the pad for the sheet. As a result, the manufacturing equipment is changed and the manufacturing cycle time is extended. Thus, it is possible to easily produce a composite molded base fabric capable of producing a sheet pad having an increased number of members without causing problems such as.

  As the fiber material constituting the composite molded base fabric composed of the nonwoven fabric in the present invention, known base fabrics used in sheet pads can be used without limitation, and in particular, rayon fiber, nylon fiber, polyester fiber, polypropylene fiber. It is preferable to use a nonwoven fabric such as

  As the material constituting the foam block in the present invention, known resin foams can be used without limitation, specifically, soft, semi-rigid or rigid polyurethane foam, polyethylene foam, polypropylene foam, polystyrene foam, Examples include EVA foam and phenol resin foam. The foam block having a predetermined shape may be molded by molding or may be formed by cutting from a slab foam.

  FIG. 1 is a perspective view showing a state in which a composite molding base fabric of the present invention is mounted on a molding die in a sheet pad manufacturing method. The composite molded base fabric 10 that has been sewn and mounted with a foam block is attached to the upper die 43 of the molding die 46 in which the upper die 43 and the lower die 41 are fixed by a hinge so as to be opened and closed. Locked and mounted. The lower mold 41 is provided with an insert fitting 45 that is an example of another sheet pad constituent member. Other members, such as hook-and-loop fasteners, are provided as necessary. In this state, when a predetermined amount of the foamed stock solution composition for forming the flexible polyurethane foam is supplied to the lower mold 41 and the foamed stock solution composition is foamed and cured by closing the mold, the insert fitting 45, the composite molded base fabric 10 and the like are integrated. A sheet pad is formed.

  The composite molded base fabric 10 has a necessary portion sewn so as to have a three-dimensional shape along the shape of the upper mold on which a cut base fabric formed by processing a raw fabric (not shown) into a predetermined shape is attached, A foam block is mounted. Attaching and fixing the foam block to the cut base fabric may be performed using an adhesive, a pressure-sensitive adhesive, a double-sided pressure-sensitive adhesive tape, etc., but as described above, the pocket-forming base fabric should be sewn and formed. However, since it can be performed using the same sewing apparatus as that for sewing into a three-dimensional shape, it is not necessary to install a new adhesive application facility and the like, which can be easily performed at low cost, and is preferable.

  FIG. 2 is a plan view illustrating a shape in which the foam block 21 is formed in the pocket 12 and attached to the cut base fabric 23. The cutting base fabric 23 may be formed by cutting using a cutter or the like, or may be formed by punching using a Thomson blade or the like, but punching is simple and suitable (cutting step) ). The cut base fabric 23 is processed into a three-dimensional shape along the unevenness of the upper die by stitching the broken line portion exemplified in 16.

  Further, in the present invention, the pocket 12 containing the foam block 21 is provided at a predetermined position of the cut base fabric 23 (pocket formation step) and used as the composite molded base fabric 10. The pocket forming base fabric constituting the pocket 12 may be the same material as the cut base fabric 23 or a different base fabric, but it is preferable to use the same base fabric. A small hole 14 formed at the center of the foam block 21 is a locking hole for inserting the composite molded base fabric 10 after sewing into a locking pin when the mold base as shown in FIG. 1 is mounted. is there. A small hole 15 in the cut base fabric indicates a sewing position of the pocket 12. The small holes 14 and 15 may be formed by punching at the same time as the punching process when the cut base fabric 23 is formed by punching. Also good. The formation of the small holes 15 is preferable because the sewing position of the pocket 12 can be easily displayed without being displayed by drawing or the like.

  FIG. 3 is a cross-sectional view taken along the line XX of FIG. 2 of the pocket 12 that houses and closes the foam block 21. The pocket 12 is formed by fixing the pocket forming base fabric 25 at a predetermined position designated by the four small holes 15 of the base fabric 23 by sewing (pocket forming step). A foam block 21 is accommodated in the pocket 12. A locking hole 29 is formed in the foam block 21, and a hole 27 is formed in the cutting base fabric 23 at the position of the locking hole 29 of the foam block 21. The composite molded base fabric 10 is attached to a molding die. When this is done, it is locked to a locking pin erected on the mold through the hole 27, and prevents the foam block position from fluctuating due to the movement of the liquid during foaming of the foamed stock solution composition. Play.

  FIG. 4 is a development view of the pocket forming base fabric, and FIG. 5 is a view showing that the pocket forming base fabric is folded and attached to the cut base fabric 23 to form a pocket having one open state, and the foam block 21 is placed in the pocket. It is the perspective view which showed the state to accommodate. The foam block 21 is accommodated in the direction of the arrow, the opening is closed by folding the base fabric 26 of the pocket forming base fabric of the opening, and the pocket 12 containing the foam block 21 is sewn along the crease 28. (Foam block mounting process).

  A window hole 30 is formed near the center of the surface constituting the wall surface of the pocket forming base fabric. This window hole 30 is for contacting and foaming the foam block containing the foamed stock solution composition during foam curing, and as a result of such adhesion, the foam block 21 becomes a sheet pad. The problem of being fixed inside and moving when subjected to force is solved. If the foam block 21 is hermetically sealed in the pocket 12 without forming the window hole 30, the foam block 21 moves in the pocket as a result of not being bonded and fixed, resulting in an uncomfortable feeling as a sheet.

  FIG. 6 is a front view of a sheet pad in which a foam block is embedded in the side portion and a partial cross-sectional view illustrating the side portion. The seat pad 50 has a seat surface portion 54 and convex side portions 52 formed on both sides of the seat surface portion 54, the insert metal fitting 45 on the seat surface portion, the foam block 21 on the side portion, and the back surface. On the side, cutting base fabrics 23 are integrated by embedding or bonding, respectively.

The perspective view which showed the state which mounted | wore the composite shaping | molding base fabric with the shaping die Plan view illustrating a composite molded base fabric in which a foam block is accommodated in a pocket. Cross-sectional view of the closed pocket containing the foam block Development of pocket forming base fabric A perspective view showing a state in which a pocket forming base fabric is folded and attached to a cut base fabric to form a pocket that is open on one side and accommodates a foam block Front view of sheet pad with foam block embedded in side part and partial sectional view illustrating side part

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Composite molding base fabric 12 Pocket 21 Foam block 23 Cutting base fabric 46 Molding die 50 Sheet pad

Claims (4)

A sheet pad base fabric comprising a nonwoven fabric, attached to the inner surface of a molding die, supplied with a foamed stock solution composition that forms a flexible polyurethane foam, and foamed and cured in the molding die to form an integrated sheet pad And
A composite molded base fabric characterized in that a foam block having a higher hardness than that of the flexible polyurethane foam is mounted in at least one place. A manufacturing method of a base fabric for a seat pad, which is made of a nonwoven fabric and is attached to the inner surface of a molding die and integrated with foam curing of a foaming stock solution composition forming a flexible polyurethane foam supplied into the molding die. There,
A cutting process for cutting a raw fabric into a cut base fabric, a pocket forming step for forming a pocket in at least one location on the cut base fabric, and a foam block having higher hardness than the flexible polyurethane foam in the pocket A method for producing a composite molded base fabric for a seat pad, comprising: a foam block mounting step in which a pocket is sealed to form a composite molded base fabric.   The method for producing a composite molded base fabric according to claim 2, wherein at least one window hole is formed in the pocket. The method for producing a composite molded base fabric according to claim 2 or 3, wherein a locking hole is formed in the foam block.

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