JP2008006263A - Composite seat spring material for automobile seat and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a composite seat spring material for an automobile seat stabilizing a tensile resilient modulus by suppressing dispersion in the tensile resilient modulus of a reinforcing cloth. <P>SOLUTION: The reinforcing cloth 12 is formed by having a textile 15 and a coating rubber 17 being stuck to fix intersections between warps and woofs of the textile 15. A single reinforcing cloth 12 is cut and separated to form two sectional reinforcing cloths 12a and 12b. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a composite seat spring material for an automobile seat composed of a two-part reinforcing cloth provided separately and a center rubber attached so as to cover the separated portion, and a method for manufacturing the same.

The automobile seat has a structure in which a urethane pad covered with a skin material is supported by a spring material fixed to a frame in order to enhance ride comfort.
This spring material is usually formed from a plurality of metallic S springs. However, since the spring material using the S spring supports only a part of the urethane pad, sufficient riding comfort cannot be obtained in a dynamic environment in which gravity acceleration is applied in the front-rear and left-right directions.

  Therefore, as a spring material that can support the urethane pad on a surface wider than the S spring, a rubber sheet is attached between two sections of reinforcing cloth, and the rubber sheet between the two sections extends to provide a wide range of spring properties. The use of a composite spring sheet material has been proposed. (See Special Table 2002-514445)

JP-T-2002-514445 (paragraphs 0013 to 0015)

  However, since the two-part reinforcing cloth is only affixed to the rubber sheet while being immersed in rubber glue, the holding force at the intersection of the warp and weft is weak, the constituent yarn is easy to move, and the end Part is easy to fray. Therefore, local tensile elasticity of the composite spring sheet material may vary. In addition, since the warp and the weft of the two-compartment reinforcing fabric are not correlated, there is a possibility that the tensile elastic modulus of the two-compartments may vary.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a composite seat spring material for an automobile seat in which variation in tensile elastic modulus of a reinforcing cloth is suppressed and the tensile elastic modulus is stabilized, and a method for manufacturing the same. And

Means and effects for solving the problems

The composite seat spring material for an automobile seat according to the present invention relates to a center rubber having a spring property and a two-compartment reinforcing cloth pasted so as to protrude to both sides in the longitudinal direction through the center rubber.
And the composite sheet spring material which concerns on this invention has the following some features, in order to achieve the said objective. That is, the present invention comprises the following features alone or in appropriate combination.

  In order to achieve the above object, the first feature of the composite seat spring material according to the present invention is that the reinforcing fabric includes a woven fabric and a coat rubber attached to fix the intersection of the warp and the weft of the woven fabric. The formed two-compartment reinforcing cloth is formed by cutting and separating a single reinforcing cloth.

  According to this configuration, the intersection between the warp and weft of the woven fabric constituting the reinforcing fabric is fixed by the coat rubber, and no movement occurs in the warp and weft constituting the woven fabric, thereby suppressing variations due to local changes in elastic modulus. The In addition, since the end portion of the reinforcing cloth is also fixed with the coat rubber, the fray resistance of the end portion is also improved. Further, since the two-section reinforcing cloth is formed by cutting and separating the single reinforcing cloth, the displacement of the constituent yarns between the two-section reinforcing cloth is reduced, and the tensile elastic modulus is stabilized. .

Moreover, the 2nd characteristic of the composite sheet spring material which concerns on this invention is that the warp of the said textile fabric has faced the said longitudinal direction.
According to this configuration, it is possible to ensure the parallel state of the constituent yarns between the two sections of the reinforcing cloth, and to eliminate the deviation of the constituent yarns.

A third feature of the composite seat spring material according to the present invention is that the fabric is impregnated with an adhesive and the coat rubber is stuck thereon.
According to this configuration, the fabric and the coat rubber are firmly fixed by using the adhesive.

A fourth feature of the composite seat spring material according to the present invention is that the cut reinforcing cloth remains without being attached to the center rubber by a predetermined width in the width direction. For example, a release layer is formed in the predetermined width of the center rubber, so that the cut reinforcing cloth remains without being pasted by the predetermined width.
According to this configuration, the elasticity of the center rubber with a predetermined width is ensured, and even if there is a predetermined width, the continuity of the constituent yarns of the reinforcing fabric can be maintained, and the constituent yarns located at the end of the predetermined width are loosened. Does not occur.

  In addition, the method for producing a composite seat spring material for an automobile seat according to the present invention includes applying an adhesive layer to one entire surface of a single woven fabric, and forming a coated rubber on the entire surface to which the adhesive layer is applied. A step of covering the sheet, a step of attaching a long and narrow release sheet along the width direction to a substantially central portion in the longitudinal direction of the fabric, and a step of attaching a rubber sheet constituting the center rubber so as to cover the release sheet; , The step of integrating the fabric and the center rubber by vulcanization of the unvulcanized rubber sheet, and the width direction of the fabric along the release sheet from the opposite side of the surface on which the release sheet is stretched And a step of cutting.

  According to this configuration, the unvulcanized rubber sheet coated on the entire surface of one side of the fabric is vulcanized via the adhesive layer, so that the integration of the fabric and the rubber sheet and the integration of the rubber sheet and the center rubber are ensured. To be made. And since the fabric remains without being pasted by the width of the release sheet by the release sheet pasted at the substantially central portion in the longitudinal direction of the fabric, cutting the fabric of this portion keeps the fabric continuous. Can be separated into two compartments.

  Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings. In addition, the composite sheet spring material as embodiment of this invention was illustrated in FIG. 1 thru | or FIG. FIG. 1 is a perspective view showing an application example of a composite seat spring material to an automobile seat, FIG. 2 (a) is a top view of the composite seat spring material, and FIG. 2 (b) is a side view of the composite seat spring material. FIG. 3 is a perspective view of an attachment portion formed on the composite seat spring material.

  FIG. 2 shows the main body of the composite sheet spring material before the attachment portion is formed. The composite sheet spring material 11 is divided into two sections of reinforcing cloths 12a and 12b, which are separated from each other with a predetermined width w, and the two sections of reinforcing cloth 12a and 12b so that the portion of the predetermined width w is substantially in the center. The center rubber 11 attached near the center of the main part is a main component. Two sections of reinforcing cloths 12a and 12b protrude from both sides of the center rubber 11, and mounting portions corresponding to the vehicle type described later are provided at the protruding portions.

  As shown in FIG. 2B, the reinforcing cloths 12a and 12b are applied in a state where the adhesive 16 is impregnated and coated by dipping or the like on both surfaces of the woven fabric (base cloth) 15, and the adhesive 16 is applied. The entire surface of one side is coated with a coat rubber 17 and integrated by vulcanization. The reinforcing cloths 12a and 12b are formed by cutting a center line L of a single woven fabric 15 (which is cut into a rectangular shape in the illustrated example) with a coat rubber 17 integrated with an adhesive 16 on one side. Thus, it is separated into two sections. For this reason, the warp and weft (in particular, the warp in the illustrated example) of the woven fabric have a mutual relationship between the reinforcing fabrics 12a and 12b. In particular, since the warp is oriented in the longitudinal direction of the two-compartment reinforcing fabrics 12a and 12b, the warp yarns of the two-compartment reinforcing fabrics 12a and 12b can be maintained in the longitudinal state.

  The woven fabric (base fabric) 15 is formed by weaving warps and wefts. The material of the warp and the weft is any one of nylon, aramid, polyester, polybenzoxazole, cotton, or a combination thereof. The form of the warp and the weft may be either a filament yarn or a spun yarn, and may be either a single-component twisted yarn or a blended yarn. The weaving configuration may be any of twill weave, satin weave, plain weave, and the like.

  The adhesive 16 is not particularly limited as long as it can exhibit the adhesiveness between the yarn constituting the fabric and the coat rubber. However, it is preferable to use an RFL treatment solution. This RFL treatment liquid is a mixture of an initial condensate of resorcin and formaldehyde mixed with a rubber latex. In this case, it is preferable that the molar ratio of resorcin and formaldehyde is 1: 2 to 2: 1 in order to increase the adhesive force. It is. If the molar ratio is less than 1/2, the three-dimensional reaction of resorcin-formaldehyde resin proceeds too much and gels. On the other hand, if the molar ratio exceeds 2/1, the reaction between resorcin and formaldehyde does not progress so much. Power will be reduced. As the rubber latex, styrene-butadiene-vinylpyridine terpolymer, hydrogenated nitrile rubber, chloroprene rubber, nitrile rubber and the like can be used. The base fabric is dipped in the RFL treatment solution, dried, and then subjected to a predetermined heat treatment to form a rubber composition adhesive layer around the yarn constituting the fabric and on the fabric surface in a coated state.

  The rubber compound for forming the coat rubber 17 is not particularly limited as long as it is cured by vulcanization. Natural rubber (NR), isoprene rubber (IR), nitrile rubber (NBR), hydrogenated nitrile rubber (HNBR), chloroprene rubber (CR), chlorosulfonated polyethylene (CSM), ethylene propylene diene monomer (EPDM), ethylene propylene A copolymer (EPR), styrene butadiene rubber (SBR), fluorine rubber, silicon rubber, or the like is used.

  The coat rubber 17 is a thin film having a thickness of 0.05 mm to 0.5 mm, and is pasted on the entire surface of one side of the woven fabric to which the adhesive is applied, using a laminating apparatus such as a calender roll. By vulcanizing the coat rubber 17, the intersection of the warp and the weft of the fabric 15 is fixed via the coat rubber 17. A center rubber 13 and reinforcing cloths 12a and 12b described later are also integrated.

  The center rubber 13 shown in FIG. 2B is cut into, for example, a quadrilateral shape, and has a thickness (1 to 2 mm) that can exhibit a spring property corresponding to the weight of an occupant sitting on the automobile seat. The rubber compound for forming the center rubber 13 is not particularly limited as long as it can exhibit a predetermined spring property. Natural rubber (NR), isoprene rubber (IR), nitrile rubber (NBR), hydrogenated nitrile rubber (HNBR), chloroprene rubber (CR), chlorosulfonated polyethylene (CSM), ethylene propylene diene monomer (EPDM), ethylene propylene A copolymer (EPR), styrene butadiene rubber (SBR), fluorine rubber, silicon rubber, or the like is used.

  FIG. 3 shows attachment portions 20 formed at both ends in the longitudinal direction of the reinforcing cloths 12a and 12b. The attachment portion 20 is provided with folded portions 21 at both ends in the longitudinal direction of the reinforcing cloths 12a and 12b, a metal shaft 21 is passed through the folded portion 21, and the folded portions 21 are integrated by bonding or / and sewing. , By forming a plurality of hook holes 22 along the shaft 21. In particular, the folded portion 21 can be easily integrated by pasting the surfaces of the coat rubber 17 together and vulcanizing under pressure.

  As shown in FIG. 1, the composite seat spring material 11 in which the attachment portion 20 is formed is hooked on a hook portion (not shown) of the hole of the attachment portion 20 in the central space of the frame 1 of the seat foundation and hooked on the attachment portion 20. By dispersing the force with the shaft 21, the frame 1 is attached in a predetermined tension state. On the frame 1, the interior of the sheet is filled with a urethane pad 2, and the seat body provided with the skin material 3 on the exterior is mounted so as to be mounted. The load of an occupant riding on the seat body acts on the composite seat spring material 11 via the urethane pad 2, and a predetermined spring property is imparted by the seat spring material 11.

Next, a method for manufacturing the composite sheet spring material 11 described above will be described with reference to FIGS.
[Reinforcing cloth forming process]
As shown in FIG. 4 (b), the fabric (base fabric) 15 in FIG. 4 (a) includes a solid of resorcin-formaldehyde-latex treatment liquid (RFL treatment liquid) or a solid of this solid and rubber paste. The adhesive layer 16 laminated with is impregnated and attached to at least one side of the entire surface.

  As shown in FIG. 4 (c), a coat rubber 17 made of unvulcanized rubber and having a thickness of 0.05 to 0.5 mm is attached to the entire surface of one side where the adhesive layer 16 is formed by a calender roll or the like. Is done. As shown in the drawing, the reinforcing cloth 12 composed of a laminated body is made based on a single fabric 15.

[Center rubber formation process]
As shown in FIG. 5A, a cellophane tape that becomes the release sheet 18 is pasted across the width direction of the central portion in the longitudinal direction of the reinforcing cloth 12. As shown in FIG. 5B, a rubber sheet 13 forming the center rubber 13 is pasted so as to cover the release sheet 18.

[Integration process by vulcanization]
By vulcanizing the state shown in FIG. 5B (particularly the coat rubber 17), the reinforcing cloth 12, the coat rubber 17, and the center rubber 13 are integrated.

[Reinforcing cloth separation process]
As shown in FIG. 5C, the release tape 18 and the reinforcing cloth 12 are cut along the center line L by cutting means such as a scissors and a cutter. Since the reinforcing cloth 12 of the part of the release tape 18 (the part having the predetermined width w) is not attached to the center rubber 13, the reinforcing cloth 12 of this part remains unattached.

[Mounting part formation process]
As shown in FIG. 3, appropriate attachment portions 20 corresponding to the vehicle type are formed at both ends in the longitudinal direction of the reinforcing cloth 12.

  As described above, in the composite sheet spring material according to this embodiment, the intersection of the warp and weft of the reinforcing cloth 12 is fixed via the coat rubber, so that the movement of the constituent yarn of the reinforcing cloth 12 is fixed. , Local variations in tensile modulus due to movement are suppressed.

  Further, since the constituent yarns of the two sections of the reinforcing fabrics 12a and 12b are continuous in the longitudinal direction and the width direction, there is no deviation in the longitudinal direction and the width direction between the constituent yarns of the two sections. Therefore, there is no unevenness in tensile elasticity due to deviation, and the tensile elastic modulus is stable in the longitudinal direction and the width direction.

  Since the portions corresponding to the predetermined width w are separated from the center rubber so that the portions corresponding to the predetermined width w can hang down on both sides, the portions corresponding to the predetermined width w are in the middle of the reinforcing cloths 12a and 12b. No fraying of the constituent yarns. Since the end of the part that can hang down is also via the coat rubber 17, it will fray. Therefore, the fraying resistance of the reinforcing cloths 12a and 12b is greatly improved.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications are possible as long as they are described in the claims.
For example, the arrangement of the constituent yarns of the reinforcing cloth 12 is not limited to the vertical and horizontal arrangement as shown in FIG.
The center rubber may be an unvulcanized rubber and vulcanized at the same time as the coating rubber is vulcanized.
Further, the release tape 18 may be left as it is, or the release tape 18 may be peeled off as an unnecessary part.

  First, as the center rubber, an unvulcanized rubber sheet having the composition shown in Table 1 was prepared.

  Separately, a plain woven canvas using a filament yarn of 66 nylon fibers of 1400 dtex for both warp and weft as a reinforcing fabric was prepared.

  An RFL treatment solution shown in Table 2 was immersed in this base fabric, dried at 120 ° C., and then heat treated at 200 ° C. for 2 minutes to form an adhesive layer on at least one entire surface of the canvas.

  Next, a reinforcing cloth was formed by passing the base cloth through a calender roll and attaching a 0.15 mm thick coated rubber (unvulcanized state) made of the composition shown in Table 3 on one side.

  Next, the reinforcing cloth is set so that the warp yarn is in the longitudinal direction using a shaft having a diameter of 3.2 mm in a mold having a dimension of 365 mm, and the reinforcing rubber is adhered so that the shaft is wound and the coated rubbers are bonded to each other. Both ends in the longitudinal direction were folded back to form a mounting portion having a length of 25 mm. A cellophane tape having a width of 32 mm was attached to the center of the reinforcing cloth as a release sheet. The center rubber cut to a thickness of 1.4 mm and a length of 75 mm was stuck on the center in the longitudinal direction.

  Subsequently, the reinforcing cloth to which the center rubber was attached was vulcanized under the conditions of 165 ° C., 5 minutes, 0.3 MPa, and the center rubber was integrated with the reinforcing cloth via the coat rubber. Moreover, the said attaching part was integrated simultaneously by vulcanization. After vulcanization, the sheet was cut to a width of 230 mm, the release sheet made of cellophane tape was cut with scissors in the width direction, and the reinforcing cloth was separated to obtain a composite sheet spring material. The release sheet was removed as unnecessary.

  In the obtained composite sheet spring material, the intersection of the warp and weft of the reinforcing fabric was fixed by the vulcanized coat rubber. Moreover, the arrangement | sequence of each component thread | yarn in the two-compartment reinforcement cloth located in both the longitudinal directions of a center rubber became what was continuous between two compartments.

Below, the result of having measured the variation of the spring constant of the composite sheet spring material which concerns on the Example mentioned above with the tension tester is demonstrated. As a comparative example, a composite sheet spring material made of the same material as that of the example was used except that the reinforcing cloth was separated in advance and pasted on both sides of the center rubber.
Jigs 52 and 53 for holding both ends of the composite sheet spring material are attached to the tensile testing machine 51 shown in FIG. A composite sheet spring material is set on the jigs 52 and 53. Then, the composite sheet spring material is pulled in the extension direction at a speed of 5 mm / min, and the elongation (L0) at an elongation rate of 2.6% and the tension (L1) at an elongation rate of 4.2% (at 2.6%) The spring constant K = (T1-T0) / (L1-L0) was calculated from the measured value.

As for the spring constant K of the composite sheet spring material according to this example, when the n number (number of tests) was 36, the average value was 31.7 N / mm, and the standard deviation was 0.76 N / mm. On the other hand, the spring constant of the composite sheet spring material of the comparative example formed by separating the reinforcing fabric in advance is n1.5 (number of tests), the average value is 31.5 N / mm, and the standard deviation is 2.04 N. / Mm.
Therefore, the composite sheet spring material of the present embodiment, which is separated after the reinforcing cloth is integrated and vulcanized, clearly has less variation in the spring constant than the composite sheet spring material of the comparative example in which the reinforcing cloth is separated in advance, It is clear that the tensile modulus is stabilized.

  The composite seat spring material according to the present invention can be used for automobile seats. There are various types of automobile seats depending on the type of automobile.

It is a perspective view which shows the example of application to the vehicle seat of the composite seat spring material of this invention. It is a figure which shows the structure of the main-body part of the composite seat spring material of this invention. It is a perspective view of the attaching part formed in the composite seat spring material of this invention. It is a figure which shows the manufacturing process of the composite sheet spring material of this invention. It is a figure which shows the manufacturing process of the composite sheet spring material of this invention. It is a front view which shows the state of a tension test.

Explanation of symbols

11 Composite seat spring material 12, 12a, 12b Reinforcement cloth 13 Center rubber 15 Woven cloth (base cloth)
16 Adhesive layer 17 Coat rubber 18 Release tape 20 Mounting part w Predetermined width

Claims (5)

A composite seat spring material for an automobile seat comprising a center rubber having a spring property and a two-part reinforcing cloth stuck so as to protrude to both sides in the longitudinal direction through the center rubber,
The reinforcing cloth is formed by including a woven fabric and a coat rubber attached to fix the intersection of the warp and the weft of the woven fabric,
The two-part reinforcing cloth is a composite seat spring material for an automobile seat, which is formed by cutting and separating a single reinforcing cloth.   The composite seat spring material for an automobile seat according to claim 1, wherein the warp of the woven fabric faces in the longitudinal direction.   The composite seat spring material for an automobile seat according to claim 1 or 2, wherein the fabric is impregnated with an adhesive and the coat rubber is stuck thereon.   The composite seat spring material for an automobile seat according to any one of claims 1 to 3, wherein the cut reinforcing cloth remains without being attached to the center rubber by a predetermined width in the width direction. A method for producing a composite seat spring material for an automobile seat comprising a center rubber having a spring property and a two-part reinforcing cloth pasted so as to protrude on both sides in the longitudinal direction through the center rubber,
Applying an adhesive layer to the entire surface of at least one side of a single woven fabric, and coating an unvulcanized rubber sheet to form a coat rubber on the entire surface of the adhesive layer;
A step of attaching a long and narrow release sheet along the width direction to the substantially central portion in the longitudinal direction of the fabric, and attaching a rubber sheet constituting the center rubber so as to cover the release sheet;
A step of integrating the fabric and the center rubber by vulcanization of the unvulcanized rubber sheet;
And a step of cutting the fabric in the width direction along the release sheet from the opposite side of the surface on which the release sheet is stretched.

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