JP2009268579A - Composite cushion body and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushion body capable of adjusting flexibility corresponding to parts of a seat and improving the moisture-absorbing property by absorbing moisture generated from a human body and emitting it. <P>SOLUTION: This composite cushion body includes a cushion layer F consisting of plastic foam body, and a fiber accumulation body 5 having a state completely covered inside the plastic foam body or a state where a part of its surface is exposed to the surface of the plastic foam body, and is fixed with locking members 3 exposed to the surface of the plastic foam body. This composite cushion body is manufactured by disposing the locking members at recessed parts provided in the upper face of a projection extending from the base to the upper part of a foaming mold, disposing the fiber accumulation body at a predetermined position of the base of the foaming mold, filling the foaming mold sealed by a lid with molding resin composition, and foaming and molding the molding resin composition. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to a composite cushion body used as a cushion material for seats for vehicles such as automobiles and indoors, and a method for manufacturing the same.

In a cushion material for a seat of an automobile or the like, a molded body of a polyurethane foam (hereinafter sometimes simply referred to as “cushion material”) that is generally excellent in elasticity is used as a seat pad. A seat for an automobile or the like is configured by mounting such a cushion material on a support frame and covering it with a skin material made of a fiber fabric or the like.
Since the cushion material has a low surface strength, a proposal has been made to improve the friction with the support frame by improving the surface structure with a reinforcing material obtained by laminating and integrating a woven fabric layer and a nonwoven fabric layer composed of single fibers. (Patent Document 1).

In addition, the seat cushion in the seat assembly for automobiles, the cover side of the seat side corner of the seat back, and the appearance of the mating part with the seat back board are the criteria for judging the appearance and quality of the seat. Therefore, Patent Document 2 proposes a seat pad in which polyester cotton subjected to half-needle punching that is hardened by impregnating urethane into the side portion of the seat pad is integrally attached.
In the seat pad according to Patent Document 2, the side portion of the seat pad is made of polyester cotton subjected to a half needle punch that has been hardened by impregnation with urethane, and is covered with a large tension thereon. It is said that even if the tension is stretched, it will not lose its tension, and the shape of the corner portion can be sharp and attractive.

  Also, cushion materials made of polyurethane foam and other foams are poorly breathable, so they will cause stuffiness in members that are in close contact with humans, and are likely to generate nitrogen-containing toxic gases during combustion. Some problems have been pointed out from the standpoint of safety and environmental protection, such as the use of chlorofluorocarbon gas sometimes destroying the upper ozone layer of the atmosphere.

  On the other hand, it has been proposed to use solid cotton or non-woven fabric mainly composed of synthetic fibers and fixed with binder fibers or the like, with the aim of improving air permeability and environmental protection or recycling. Solid cotton or non-woven fabric mainly composed of synthetic fibers is a so-called mat-like material that is web-formed through a card machine and then bonded with binder fibers. Can be easily used for close moldings, but difficult to use for irregular or deep-drawn moldings. Stability of molded products and uniformity of fiber density in irregular and deep-drawing products There was a problem that was inferior. In addition, there are problems in cost because of the large number of processes.

  Therefore, in recent years, in order to improve and stabilize the moldability, a pulverized product obtained by cutting the mat-shaped synthetic fiber solid cotton as described above into a square shape by a pulverizer or the like is formed, and this pulverized product is placed in the mold. Or a fiber structure manufactured by blow molding a ball-shaped cotton in which polyester-based short fibers and thermal adhesive fibers are intertwined (for example, see Patent Document 3). , See Patent Document 4).

Furthermore, in Patent Document 5, the solid cotton made of synthetic fibers is excellent in molding stability, uniformity of fiber density, cost, etc., and the fiber solid cotton used for cushions, sound absorbing materials, etc. A fiber solid cotton that can be easily obtained even in a deep-drawn molded body and a fiber solid cotton comprising a main fiber having a crimp of fiber length of 1 to 10 mm and a crimped fiber and a similar binder fiber have been proposed. .
However, the cushioning material by the fiber structure described in Patent Documents 3 to 5 is expensive because a web forming process and a dedicated mold for blow molding are necessary, and the obtained fiber solid cotton is also There are basic problems such as being easy to sag against compression or being unable to attach the engaging element for attaching the skin material integrally at the time of molding.

JP 2005-177198 A JP-A-7-1117060 Japanese Patent Laid-Open No. 11-147230 JP 2001-207360 A JP 2001-262455 A

  Regarding the cushion material made of foam, it has been improved by using a fiber nonwoven fabric as a reinforcing material for the bottom and sides, but for example, the problem of urethane foam itself, that is, adjustment of flexibility, hygroscopicity No improvements have been made. Cushioning materials for seats, especially automobile seats, are often used for a long time, and cushioning materials for such applications can adjust the flexibility corresponding to the part of the seat and absorb and release moisture emitted from the human body. A cushion material with improved hygroscopicity is desired.

As a result of intensive studies, the present inventors have developed a cushioning material that can improve the above-mentioned problems of the cushioning material, in particular, the adjustment of the flexibility corresponding to the part of the seat and the improvement of the hygroscopic property that absorbs and releases moisture emitted from the human body. The present inventors have found that this can be solved by combining a cushion layer made of a synthetic resin foam and a fiber aggregate exposed inside or at least one surface of the synthetic resin foam.
That is, the present invention
(1) A cushion layer made of a synthetic resin foam, and a fiber assembly in a state of being completely encapsulated inside the synthetic resin foam or a part of the surface exposed on the surface of the synthetic resin foam A composite cushion body characterized by containing
(2) The composite cushion body according to (1), which is fixed in a state where a locking member is exposed on the surface of the synthetic resin foam,
(3) The synthetic resin to which the locking member is fixed in a state where the fiber assembly is completely encapsulated inside the synthetic resin foam or a state where the surface thereof is exposed on the back surface of the synthetic resin foam The composite cushion body according to (2) above, wherein a plurality of communication holes having openings are provided between the surface of the foam and the fiber assembly.
(4) After disposing the locking member in the recess provided on the upper surface of the protrusion extending upward from the bottom surface of the foam mold, and further disposing the fiber assembly at a predetermined position on the bottom surface of the foam mold A method for producing a composite cushion body comprising the steps of: filling a foam molding mold sealed with a lid with a molding resin composition, and foaming and molding the molding resin composition;
(5) A locking member is disposed in a recess provided on the upper surface of a protrusion extending from the bottom to the top of the foam molding die, and after a certain amount of the molding resin composition is introduced into the die, fibers are accumulated on the inner surface. A composite comprising a step of attaching a lid of a molding die provided with a body to the molding die, filling the molding resin composition into the molding die, and foaming and molding the molding resin composition Manufacturing method of cushion body,
(6) A locking member is disposed in a recess provided on the upper surface of the protrusion extending upward from the bottom surface of the foam molding die, and after a certain amount of the molding resin composition is introduced into the mold, the bottom surface of the molding die or A fiber assembly supported by a plurality of supports provided on the inner surface of the lid of the molding die is disposed, and the molding resin composition is filled in the molding die, and the molding resin composition is foamed. A method for producing a composite cushion, comprising a step of completely encapsulating a fiber aggregate with a foam, or a step of forming a fiber aggregate with the surface exposed on the back surface of a synthetic resin foam;
(7) The method for producing a composite cushion body according to (6), wherein the support is molded from the same foam as a cushion layer made of a synthetic resin foam,
(8) After molding the composite cushion body including the fiber aggregate, the surface side to which the engagement member of the composite cushion body is fixed, the fiber aggregate completely encapsulated with the foam, or the surface thereof The method for producing a composite cushion body according to any one of (5) to (7), wherein a plurality of open communication holes are mechanically opened between the fiber aggregate exposed on the back surface of the synthetic resin foam, And (9) the support is a resin molded body or a metal molded body into which the molding resin composition does not enter, and after the foaming molding of the molding resin composition, the supporting body is removed to obtain a locking member. A plurality of open communication holes are provided between the surface side fixed with the fiber aggregate fully encapsulated with the foam, or the fiber aggregate whose surface is exposed on the back surface of the synthetic resin foam. (6) The method for producing a composite cushion body according to
Is to provide.

As described above, the present invention enables adjustment of the flexibility of the cushion material by embedding the fiber aggregate in the urethane foam cushion layer, and provides moisture absorption by providing an opening communicating with the fiber aggregate. can do. Furthermore, the amount of foamed resin having a volume corresponding to the fiber aggregate can be reduced, and the fiber aggregate can be recovered, so that the load required for disposal and processing of the urethane foam cushion layer can be reduced.
In addition, it is difficult to integrally attach the engaging element for attaching the skin material in the cushion material made of only the fiber aggregate, but the composite cushion material of the present invention is a so-called foam molding, which is used in conventional foam molding. Since mold-in molding is possible, a composite cushion body with an engagement element can be obtained by using a molding die in which an engagement element is arranged at a desired position, in accordance with various designs of the cushion material.

The present invention relates to a cushion layer made of a synthetic resin foam and a fiber accumulation in a state of being completely encapsulated in the synthetic resin foam or a part of its surface exposed on the surface of the synthetic resin foam It is a composite cushion body characterized by including a body.
Polyurethane resin foam is widely used as a cushion layer made of synthetic resin foam, but cushion material made only of urethane is homogeneous, but in the seat cushion material, it corresponds to each part such as the center and sides. Therefore, it is difficult to adjust the flexibility, in other words, the hardness. In the cushion material used for a long time, it is important to adjust the flexibility at the center and the side. Since the maximum weight is applied to the center of the bottom of the cushion material, the cushion material sags severely, and recovery thereof is difficult, so high hardness is desired. On the other hand, the side portions are less likely to be heavy, so rather high flexibility is often preferred.
In the present invention, the entire composite cushion body can be flexibly integrated by adjusting the flexibility and hardness of the fiber assembly by combining and integrating the fiber assembly at an arbitrary part such as the front surface, center, and back surface of the synthetic resin foam. The sexuality is adjusted to a high range. Further, if necessary, it is possible to embed a fiber assembly more flexible than the foam so that the structure is more flexible than the cushion material made of only the foam.

As the resin composition for molding the synthetic resin foam of the present invention, any resin used for the cushioning material can be used, for example, selected from polyurethane resins, vinyl chloride resins, polyolefin resins, various synthetic rubbers, etc. A resin composition in which a desired additive selected from a foaming agent, a lubricant, a filler, a colorant, a flame retardant, various stabilizers and the like is blended with the obtained resin can be given. Usually, a polyurethane-based resin composition is preferably used from the viewpoint of stability of bubbles, elastic characteristics, durability, and the like.
As the polyurethane resin composition, a conventionally known foamable polyurethane composition can be suitably used. The hardness of the cured product can also be adjusted within the range of known techniques.
More specific foamed polyurethane will be described. The foamed polyurethane is a polyol, a polymer polyol in which polymer particles obtained by radical polymerization of acrylonitrile and styrene in the polyol are dispersed, water as a foaming agent, and a silicone surfactant. Such as a foam stabilizer, a catalyst such as an amine or a tin compound, and a crosslinking agent if necessary, a flame retardant, a pigment, various stabilizers, and the like, and an organic polyisocyanate. Examples of the polyol include polyether polyols having an average molecular weight of 400 to 10,000, preferably 1500 to 6000 obtained by adding propylene oxide or ethylene oxide to polyglycerin, and examples of the polyisocyanate include 2,4- or Representative examples include 2,6-tolylene diisocyanate and 4,4′-diphenylmethane diisocyanate. Examples of the amine include tertiary amines such as triethylamine, tributylamine, and dimethylethanolamine. Examples of the tin compound include dibutyltin laurate.
The commercially available raw material liquid for urethane foam is composed of two liquids, a liquid in which water or a catalyst is added in advance to the above polyol and a liquid composed of isocyanate, and the liquid is stirred immediately before being poured into a mold. A method of mixing, immediately pouring the mixed solution into a mold, and performing polymerization and molding simultaneously with foaming is used.

Examples of the fiber aggregate used in the present invention include the above-described fiber aggregate having many voids therein, such as short fiber entanglement, long fiber entanglement, non-woven fabric and laminate thereof. Those subjected to processing such as needle punching and partial fusion are also included. These fiber aggregates are effective for adjusting flexibility and hygroscopicity.
By performing partial fusion, the so-called sag reduction in volume due to a long-term load of the fiber assembly can be improved. That is, by making the fiber aggregate layer have a partial fusion structure, a linear or planar fusion part can be formed in the fiber accumulation body, and movement of fibers in the fusion bond part is restricted. Thus, the structure resists the load.
Specific examples of fibers of the fiber assembly include polyester, polyamide, polyolefin, polyvinyl alcohol, synthetic fibers such as core-sheath type heat-fusible composite fibers in which the sheath component is a low melting point polymer, cotton, wool, etc. Mention may be made of natural fibers and mixtures thereof.
Further, wet heat fusible fibers such as polyvinyl alcohol and ethylene-vinyl alcohol copolymer can be mixed in the fiber assembly to form arbitrary voids and voids therein. Such voids can further adjust the hardness, weight, hygroscopicity, air permeability and the like of the fiber assembly.
Polyester fibers are preferred from the viewpoints of elasticity, bulkiness, durability, and adhesion to polyurethane. Further, hydrophilic polyester fibers are particularly preferred for enhancing moisture diffusion and moisture absorption / release.

  Furthermore, the fiber aggregate as the cushion body is used to open a short fiber, a sliver, and the like appropriately selected in terms of the cut length, fineness, crimped form, etc. of the fiber in producing the fiber aggregate from the above-mentioned fibers, After mixing at an appropriate mixing ratio, it is loaded onto the conveyor by the card layer method or air layer method, sucked as necessary to form a web on the conveyor, and further compressed into a predetermined apparent density. It is molded by hot air or heated steam at a predetermined temperature, or the web on the conveyor is finished to a specified thickness and a specified apparent density by needle punching, and heat treatment is performed in the same manner, so that the cushioning property etc. Can be adjusted.

  The mass ratio between the cushion layer made of foam and the fiber aggregate can be adjusted according to the purpose of the resulting composite. The fiber aggregate is 30 to 60% by mass for adjusting the hardness, and the hygroscopicity is improved. Is preferably 20 to 50% by mass, and 40 to 70% by mass for improving air permeability.

Moreover, in this invention, it can be set as the composite cushion body formed by fixing in the state which the latching member exposed to the surface of the synthetic resin foam. By fixing the locking member in an exposed state, it is possible to obtain convenience when attaching a skin material such as fabric and convenience when replacing the skin material.
Fixing with the locking member exposed means that the engagement element of the locking member can be engaged with the mating engagement element, etc., attached to the skin material to be attached later, etc. toward the outside of the surface. Attached to the synthetic resin foam in a state where the back side of the locking member and the synthetic resin foam are bonded, or a member protruding from the back of the locking member is embedded. To do.

  A hook-and-loop fastener is suitable as the locking member used in the present invention. As a surface fastener, a woven fabric surface obtained by knitting and weaving mainly fibers selected from polyester fibers, polyamide fibers, polyolefin fibers, polyvinyl chloride fibers, acrylic fibers, cellulose derivative fibers such as cellulose acetate, etc. Fasteners, polyester, polyamide, polyolefin, olefin vinyl acetate copolymer or saponified product thereof, polyvinyl chloride, polyurethane, polyester elastomer, polyamide elastomer, polyolefin elastomer, other thermoplastic resins or thermosetting resins, etc. A molded surface fastener obtained by molding a synthetic resin can be mentioned.

  The hook-and-loop fastener as the locking member is provided with an engaging element group having an engaging function such as a loop shape, a hook shape, a mushroom shape, and a swollen head on one surface of the base material. This surface may be a base material as it is, or a woven fabric or a net-like material may be laminated. In order to increase the peel strength between the hook-and-loop fastener and the molded body, the other surface of the base material is embedded with a group of embedded elements such as loops, hooks, bulges, irregularities, fluffs, squares, rails, etc. May be erected.

In the composite cushion body of the present invention, the locking member is fixed in a state where the fiber assembly is completely encapsulated in the synthetic resin foam or the surface thereof is exposed on the back surface of the synthetic resin foam. A plurality of communication holes having openings can be provided between the surface of the synthetic resin foam and the fiber assembly.
Sitting comfort can be adjusted by the arrangement position of the fiber assembly in the composite cushion body. In addition, by providing a plurality of communication holes having openings between the surface of the synthetic resin foam to which the locking member is fixed and the fiber assembly, sweat or the like released from the body of the seating surface may be Thus, when not in use, moisture absorbed by the fiber aggregate can be released from the opening through the communication hole, so that the seat can be released from unpleasant moisture.
The diameter and number of the communication holes are appropriately set according to the hardness of the synthetic resin foam.

The composite cushion body of the present invention is manufactured by a known method called mold forming or mold-in for obtaining a synthetic resin foam. In the first molding method of the present invention, a locking member is disposed in a recess provided on the upper surface of a protrusion extending upward from the bottom surface of the foam molding die, and further, at a predetermined position on the bottom surface of the foam molding die. After the fiber assembly is disposed, a foam molding die sealed with a lid is filled with the molding resin composition, and the molding resin composition is foamed and manufactured. According to this manufacturing method, the composite cushion body in which the fiber aggregate is exposed on the surface of the foam molded body is formed. Further, by this method, a composite cushion body is obtained that is embedded with the locking member exposed on the surface of the foam.
In order to dispose the fiber aggregate at a predetermined position on the bottom surface of the molding die, it is possible to adopt a method such as providing a pin-like projection capable of locking the fiber aggregate on the bottom surface and inserting the fiber aggregate into the pin-like projection. .

In the second molding method of the present invention, a locking member is disposed in a recess provided on the upper surface of a protrusion extending from the bottom surface of the foam molding die, and a certain amount of the molding resin composition is introduced into the mold. After that, by attaching the lid of the molding die provided with the fiber aggregate on the inner surface to the molding die, filling the molding resin composition into the molding die, foaming the molding resin composition and molding A composite cushion body in which the fiber aggregate is exposed on the back side of the foamed molded body can be produced.
In order to place the fiber aggregate at a predetermined position inside the lid of the mold, a pin-like protrusion that can lock the fiber aggregate is provided inside the lid, and the fiber aggregate is pierced into the pin-like protrusion. This method can be adopted.

  Further, in the third molding method of the present invention, a locking member is disposed in a recess provided on the upper surface of a protrusion extending from the bottom surface of the foam molding die to a predetermined amount of the molding resin composition in the mold. After the introduction, the fiber assembly supported by a plurality of supports provided on the bottom surface of the mold or the inner surface of the lid of the mold is disposed, and the molding resin composition is filled in the mold, and the molding is performed. This is a method of obtaining a composite cushion body in which the resin composition is foamed and the fiber aggregate is completely encapsulated with the foam.

  When using a support previously produced with the same resin molding as the foam, for example, a polyurethane-based foam, a urethane slab or the like is used, and the number of the fibers that can hold the mass of the fiber assembly on the bottom of the mold If a slab or the like is placed at a predetermined position, the fiber aggregate is fixed on the foamed resin composition, and the foamable resin composition flows in, the support becomes homogeneous with the foam, so the fiber aggregate is placed inside the foam. It can be embedded without any apparent support.

Further, in the third production method, when the support is composed of a resin molded body or a metal molded body into which the foamable resin composition does not enter, by removing the support after foam molding of the composite cushion body, A trace becomes a space, and a plurality of communication holes opened from the surface of the foam to the fiber assembly can be provided. By adjusting the cross-sectional area, number, length, etc. of the support, the hygroscopicity, air permeability and flexibility can also be adjusted.
More specifically, in order to hold the fiber aggregate from the bottom surface side of the mold, the fiber aggregate can be held at a predetermined position from the bottom surface of the mold, and the synthetic resin molded body into which the foamable resin composition does not enter or For example, a method of disposing a support having a required number of pin-shaped supports formed of a metal formed body at a predetermined position on the bottom surface of the forming die can be employed.

  In the method for producing a composite cushion body of the present invention, when the fiber assembly and the liquid foamable molding resin composition are contacted in the mold, about 1 to 10 mm is formed from the peripheral surface of the fiber assembly. A thing infiltrates into the fiber integrated body side, and a foaming resin impregnation layer is formed. This foamable resin-impregnated layer forms a fiber-reinforced foamable resin layer in which the fibers constituting the fiber assembly are reinforcing fibers. Therefore, by considering the constituent fibers as reinforcing fibers and considering their physical properties and density, adhesion to the foamable resin composition, etc., and designing the foamable resin-impregnated layer as a shell, the shell behaves as a unit. In addition, it is possible to provide a function of dispersing the load due to the seating and dispersing the propagation of vibration from the vehicle body side.

  In addition to using the above-mentioned support, the opening of the communication hole in the foam is a method of mechanically opening a through-hole from the surface of the foam to the fiber assembly with a drill, a rotary blade, or the like. It is also possible to use both the general opening and the above-described opening by the support.

  The present invention will be described below with reference to examples, but the present invention is not limited to the following examples.

In Examples and Comparative Examples, the locking members described below were used and evaluated by the following measuring methods.
Locking member: A band-shaped molded hook fastener made of polypropylene having a width of 10 mm (X6323-3, manufactured by Kuraray Fastening Co., Ltd.) was used.
(1) Measurement of air permeability: Measured according to JIS L 1096 A method (Fragile method).
(2) Measurement of hardness of cushion body: Measured according to JIS K 6401 method.
(3) Wear test (i) Anti-steaming property: A composite cushion body or foam cushion material is placed in an artificial climate room under an environment of 28 ± 1 ° C. and 65 ± 5% RH, and four persons weighing 65 to 70 kg are placed on it. After sitting for 60 minutes, the sense of stuffiness was sensory-evaluated with the following score, and the average score of four people was obtained.
3 points: No stuffiness.
2 points: Slightly stuffy.
1 point: I feel very stuffy.
(Ii) Cushioning and sitting comfort: During the smoldering test, the subsidence during sitting and the sitting comfort during 1 hour sitting were sensory evaluated by the following scores, and the average score of four persons was obtained.
3 points: Good without sinking when seated. Good sitting comfort.
2 points: Slight depression when sitting. Slightly inferior.
1 point: Subsidence when sitting is large. Sitting comfort is inferior.

Example 1
First, a polyester fiber having a thickness of 15 dtex and a core-sheath type polyester binder fiber having a thickness of 6 dtex and a core melting point of 160 ° C. or higher and a sheath melting point of 130 ° C. or lower are blended in a mass ratio of 60:40. Then, a fiber assembly having a thickness of 50 mm and a density of 0.045 g / cm ³ , which was entangled and heat-treated at 150 ° C. for 1 minute, was prepared.

Using this fiber assembly, a composite cushion was produced. Hereinafter, description will be given with reference to the drawings. FIG. 1 shows an example of a method for producing a composite cushion body 10 according to the present invention. As shown in FIGS. 1 (A) and 1 (A-1), the locking member 3 is mounted in the recess 2 provided on the top surface of the protrusion 1a extending from the bottom surface of the mold 1 to the top. As shown in (B), two types of foamable polyurethane raw material liquids (manufactured by Mitsui Takeda Chemical Co., Ltd., resin premix “MHR2450” (including water and catalyst) and isocyanate “TM20”) are used as the molding resin composition 4. Take out from each resin tank, mix at a weight ratio of 100: 45, immediately inject a certain amount into the mold 1, close the lid 1 ′ of the mold with the fiber aggregate 5 attached to the center of the inner surface, The mold temperature was maintained at 65 ° C. for 6 minutes for foaming. After foaming and curing the resin, as shown in FIG. 2 (A), the lid of the mold was opened, and the composite cushion body was taken out. The composite cushion body 10 having the cross section shown in FIG. 3C is obtained in which the engaging member 3 is integrally embedded in the surface of the composite cushion body 10 and the fiber accumulation body 5 is exposed at the center of the back surface. It was. 3 mmφ holes (openings) 6 communicating from the surface of the composite cushion body 10 to the inner fiber assembly were opened at a density of 1000 / m ² .
In Example 1, using the fiber assembly and the locking member described at the beginning, as shown in FIG. 1 (A-1), the molded hook fastener 3 is infiltrated into the mold recess 2 and the urethane liquid soaks into the hook surface. I inserted it so that there was no.
The thickness of the center part of the obtained composite cushion body 10 was 80 mm, and the mass ratio of the fiber aggregate in the composite cushion body was 40%. Moreover, the density of the obtained composite cushion body was 0.043 g / cm < ³ >.
In addition, as shown in FIG. 2 (A), a pin 7 that can be engaged with the fiber assembly is disposed on the surface of the central portion of the mold lid 1 ′, as shown in FIGS. 1 (A) and 1 (B). The fiber assembly 5 was temporarily fixed to the lid 1 '.
The hardness of the central part of the obtained composite cushion body was 90 N as measured by JIS K 6401 method. The peripheral portion had a hardness of 80N. The air permeability was 30 cm ³ / (cm ² · sec).
Moreover, when the obtained composite cushion body was cut | disconnected and the cross section was observed, as shown in FIG.3 (D), as for the foaming resin to the fiber integration body layer 5 side, the surrounding surface of the fiber integration body layer 5 is about 5 mm. It moved to the part and the foamable resin impregnation layer 8 was formed.
The composite cushion body obtained in this example was covered with a skin material made of polyester-processed yarn knit and subjected to a wearing test by four panelists. As a result, there was no stuffiness, and there was little sinking when seated. there were.
It should be noted that there is little sinking when seated because the foamed resin impregnated layer has a shell shape made of fiber reinforced foamed resin, and the pressure is applied to the compressive load on the composite cushion body. It is considered that the resin impregnated layer 8 has an overall effect and suppresses sinking during sitting.
The results are summarized in Table 1.

Comparative Example 1
In Example 1, a cushion body made of only polyurethane foam was obtained without using a fiber assembly. The density of the obtained cushion body is 0.042 g / cm ³ , the hardness of the central part is 85 N, the hardness of the peripheral part is 84 N, the air permeability is 3 cm ³ / (cm ² · sec), and the stuffiness is felt When sitting for a long time, it was uncomfortable.
The results are summarized in Table 1.

The composite cushion body of the present invention combines the cushion layer made of a synthetic resin and the fiber assembly, so that the flexibility of the cushion material can be adjusted, and a plurality of communication having openings in the fiber assembly is possible. Since it can provide moisture absorption by providing holes, it can be effectively used as cushioning material for seats and backrests of seats of automobiles, etc., residential chairs, office chairs, reception sofas, beds, etc. .
In addition, the method for producing a composite cushion body of the present invention can obtain the above-mentioned useful composite cushion body by a method improved from a conventionally known foam molding or mold-in molding method. And it can utilize as a manufacturing method which can reduce manufacturing cost.

FIG. 6 is an explanatory diagram of a process for manufacturing a composite cushion body according to Example 1. (A) Locking member arrangement situation explanatory drawing to a mold, (A-1) Detailed explanation drawing of a locking member arrangement situation, (B) Foamable resin inflow process explanatory drawing, (C) Foaming process of closed lid Illustration (A) The figure which shows the state which opened the lid | cover after foam molding, (B) The figure which shows the composite cushion body taken out from the shaping | molding die. It is a schematic cross-sectional view showing three aspects of the composite cushion body of the present invention, (A) an example in which the fiber aggregate is arranged on the surface side, (B) in a state where the fiber aggregate is completely encapsulated in the synthetic resin foam Example of arrangement, (C) Example of arrangement of fiber aggregate obtained in Example 1 on the back side, (D) Foamable resin impregnated layer at the boundary between the foam layer and fiber aggregate of FIG. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Foam molding die 1 'Foam molding die lid 2 Recess 3 Locking member 4 Foamable resin 5 Fiber assembly 6 Communication hole 7 Pin 8 Foamable resin impregnated layer 10 Composite cushion body F Foam cushion layer

Claims (9)

  A cushion layer made of a synthetic resin foam and a fiber assembly in a state of being completely encapsulated in the synthetic resin foam or a part of its surface exposed on the surface of the synthetic resin foam A composite cushion body characterized by that.   The composite cushion body according to claim 1, wherein the composite cushion body is fixed in a state where a locking member is exposed on a surface of the synthetic resin foam.   The synthetic resin foam in which the locking member is fixed in a state in which the fiber assembly is completely encapsulated in the synthetic resin foam or a state in which the surface is exposed on the back surface of the synthetic resin foam The composite cushion body according to claim 2, wherein a plurality of communication holes having openings are provided between the surface and the fiber assembly.   A locking member is disposed in a recess provided on the upper surface of a protrusion extending upward from the bottom surface of the foam molding die, and a fiber assembly is disposed at a predetermined position on the bottom surface of the foam molding die. A method for producing a composite cushion, comprising: filling a sealed foam molding die with a molding resin composition, and foaming and molding the molding resin composition.   A locking member is placed in a recess provided on the upper surface of the protrusion extending from the bottom to the top of the foam molding die. After a certain amount of the molding resin composition is introduced into the mold, a fiber assembly is attached to the inner surface. A composite cushion body comprising the steps of: attaching a lid of the molded mold to the mold; and further filling the mold with the molding resin composition and foaming the molding resin composition Production method.   A locking member is disposed in a recess provided on the upper surface of a protrusion extending upward from the bottom surface of the foam molding die, and after a certain amount of the molding resin composition is introduced into the die, the bottom surface of the molding die or the molding die A fiber aggregate supported by a plurality of supports provided on the inner surface of the lid is disposed, a molding resin composition is filled in a mold, and the molding resin composition is foamed to obtain a fiber aggregate. A method of manufacturing a composite cushion body, comprising: a step of completely encapsulating the foamed body with a foam, or a step of forming a fiber aggregate whose surface is exposed on the back surface of the synthetic resin foam.   The method for producing a composite cushion body according to claim 6, wherein the support is formed of the same foam as the cushion layer made of a synthetic resin foam.   After forming the composite cushion body including the fiber aggregate, the surface side of the composite cushion body to which the locking member is fixed, the fiber aggregate completely encapsulated with the foam, or the surface thereof is a synthetic resin foam. The manufacturing method of the composite cushion body in any one of Claims 5-7 which mechanically opens the several communicating hole opened between the fiber integration bodies exposed on the back surface of the body.   The support is a resin molded body or a metal molded body into which the molding resin composition does not enter, and after the foaming molding of the molding resin composition, the support is removed to fix the locking member. 7. A plurality of open communication holes are provided between the side and the fiber aggregate completely encapsulated with the foam or the fiber aggregate whose surface is exposed on the back surface of the synthetic resin foam. Manufacturing method of composite cushion body.

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