JP2013067263A - Cushion body, vehicle seat, and method of manufacturing cushion body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily manufacture a cushion body in which a plate element is arranged in a cushion body with a fiber structure constructed as the base material.SOLUTION: In the cushion body 10 having a posture control plate 110 arranged in the cushion body 100 integrally formed of a plurality of laminates of sheet fiber structures 13, 14, 15, 16, the cushion body 100 is formed by integrating the plurality of sheet fiber structures 13, 14, 15, 16 while holding the posture control plate 110 between two adjacent ones of sheet fiber structures 13, 14 adjacent to each other among the plurality of sheet fiber structures 13, 14, 15, 16.

Description

  The present invention relates to a cushion body, a vehicle seat, and a cushion body manufacturing method, and in particular, a cushion including a cushion body formed using a sheet-like fiber structure as a base material and a plate member disposed in the cushion body. The present invention relates to a body, a vehicle seat provided with a cushion body, and a method of manufacturing the cushion body.

  As cushion bodies used for vehicle seats and the like, those manufactured using urethane foam are widely known (see, for example, Patent Document 1). Patent Document 1 discloses a cushion body formed by foaming a urethane stock solution (in the middle of reaction) in a mold and formed using a plurality of stock solutions having different compositions.

  In addition, when covering the cushion body with the skin material, it is required to finish so as to suppress the generation of wrinkles and to provide a good appearance. A construction method has been proposed in which a cushion body (seat cushion pad) is lined and foam-molded with respect to the assembly) (for example, see Patent Document 2).

  On the other hand, since urethane foam has hydrolyzability, it is fragile depending on the application and has a long service life. Therefore, a cushion body constituted by a fiber structure made of polyester fiber or the like instead of urethane foam has been proposed (see, for example, Patent Document 3).

Japanese Patent No. 2950915 JP 2008-237345 A JP-A-8-318066

  By the way, for the purpose of regulating the posture of the occupant seated on the seat, a plate member having a relatively high strength may be arranged in the cushion body. However, when molding the cushion body (the portion of the cushion body that is foam-molded by the urethane foam) with urethane foam, the mounting position of the plate member relative to the cushion body is limited due to process limitations. Become. Specifically, using the method disclosed in Patent Document 2, when foaming urethane foam from the surface side of the plate member and lining foam molding of the cushion body, the urethane foam is placed on the back side of the plate member. Since it is difficult to wrap around, a plate member must be provided on the back side of the cushion body as a result.

  As described above, in the past, the mounting position of the plate member has been limited, but naturally, it is desirable that the mounting position can be freely determined by design, and in particular, it is not exposed to the outside from the viewpoint of design. It is required to arrange the plate member at the position, that is, inside the cushion body. Further, when the plate member is disposed in the cushion body, it is desirable that the operation is easily performed without much effort.

  On the other hand, since urethane foam has hydrolyzability as described above, it is fragile depending on the application, and the service life is not long. For this reason, it is conceivable to form the cushion body with a fiber structure such as polyester fiber instead of urethane foam. In this case, as described above, it is desirable that the plate member can be easily disposed in the cushion main body made of polyester fiber, and a method for manufacturing the cushion body that satisfies such requirements is required.

  Then, this invention is made | formed in view of said subject, The place made into the objective is the cushion body by which the plate member is arrange | positioned inside the cushion main body comprised by making a fiber structure into a base material, An object of the present invention is to provide a cushion body that can be easily manufactured and a vehicle seat using the cushion body. In other words, another object of the present invention is to provide a manufacturing method capable of easily manufacturing a cushion body in which a plate member is disposed inside a cushion main body configured with a fiber structure as a base material. is there.

  According to the cushion body of the present invention, the object is a cushion body having a cushion body formed by integrating a plurality of laminated sheet-like fiber structures, and a plate member disposed in the cushion body. The cushion body includes the plurality of sheet-like fiber structures in a state where the plate member is sandwiched between two adjacent sheet-like fiber structures adjacent to each other among the plurality of sheet-like fiber structures. It is solved by being formed by integrating.

  If it is said cushion body, since a several sheet-like fiber structure is integrated in the state which has arrange | positioned the plate member between two adjacent sheet-like fiber structures, formation of a cushion main body and a plate inside a cushion body The members are arranged at the same time. As a result, the number of processes is reduced, and the cushion body can be easily manufactured.

  Further, in the above cushion body, the cushion body is fastened to a mounting frame by a linear member, and the linear member is attached to one end face in the thickness direction of the plate member, and the plurality of sheet-like fibers In order to pass the linear member through the sheet-like fiber structure on the same side as the linear member as viewed from the plate member sandwiched between the adjacent sheet-like fiber structures among the structures It is preferable that the through hole is formed. In such a configuration, when integrating the plurality of sheet-like fiber structures, if the linear member is passed through the through hole, the plate member is favorably held at a predetermined position between the adjacent sheet-like fiber structures. It becomes possible.

Further, the cushion body constitutes a seat back of a vehicle seat, and the plate member is positioned when the occupant seated on the vehicle seat leans on the seat back on the back side. It is good also as being a posture regulation plate for regulating.
Furthermore, the vehicle seat provided with the cushion body of Claim 3, and the skin material which covers this cushion body is also realizable.

  Further, according to the method for manufacturing a cushion body of the present invention, the above-described problem is a cushion body formed by integrating a plurality of laminated sheet-like fiber structures, and a plate member disposed in the cushion body. A method of manufacturing a cushion body comprising: a step of disposing the plurality of sheet-like fiber structures between a set of molds that can be combined with each other; and the step of disposing the plurality of sheet-like fiber structures. Forming the cushion body by integrating a plurality of sheet-like fiber structures, and in the step of disposing the plurality of sheet-like fiber structures between the set of molds, the plurality of sheets The plurality of sheet-like fiber structures are disposed between the pair of molds with the plate member sandwiched between two adjacent sheet-like fiber structures adjacent to each other among the sheet-like fiber structures, and the cushion body The In the step of forming, is solved by integrating the plurality of sheet-like fibrous structure said plate member in a state sandwiched between said adjacent sheet-like fibrous structure.

  According to the above manufacturing method, as described above, a plurality of sheet-like fiber structures are integrated with a plate member disposed between two adjacent sheet-like fiber structures. As a result of the simultaneous arrangement of the plate member inside the main body, the number of steps is reduced, and the cushion body can be easily manufactured.

  Further, in the above manufacturing method, a step of attaching a linear member for fastening the cushion body to an attachment frame on one end surface in the thickness direction of the plate member, and among the plurality of sheet-like fiber structures, The sheet-like fiber structure on the same side as the linear member as seen from the plate member sandwiched between adjacent sheet-like fiber structures, and the plate member to which the linear member is attached A step of setting one of the molds, and a sheet-like fiber structure on the same side as the linear member, and the plate member to which the linear member is attached In the step of setting in one mold, the linear member is passed through a through hole formed in the sheet-like fiber structure on the same side as the linear member, and the set hole formed in the one mold is Of the linear member and passing the protruding part from the through-hole, which is preferable. In such a manufacturing method, by passing the linear member through the through hole and the set hole, the sheet-like fiber structure (sheet-like fiber structure on the same side as the linear member as viewed from the plate member) with respect to one mold The body) and the plate member can be easily set at a predetermined set position, and can be favorably held at the set position.

  Further, in the above manufacturing method, the plurality of sheet-like fiber structures are the plurality of sheet-like fiber structures when viewed from the plate member sandwiched between the adjacent sheet-like fiber structures. A first sheet-like fiber structure positioned on one end in the stacking direction is set together with the plate member in one of the set of molds, and a second sheet-like fiber structure positioned on the other end When the first sheet-like fiber structure is set together with the plate member in the one mold, the plate member as viewed from the first sheet-like fiber structure. The first sheet-like fiber structure is set in the one mold together with the plate member such that the second sheet-like fiber structure is placed in the other mold. set The second sheet-like fiber structure is set in the other mold by passing a convex portion provided on the other mold through a through hole formed in the second sheet-like fiber structure. In the step of disposing the plurality of sheet-like fiber structures between the set of molds, the first sheet in which the first sheet-like fiber structure and the plate member are set, and the second sheet When the other mold on which the fibrous structure is set is combined, and when the one mold and the other mold are combined, the tip of the convex portion protruding from the through hole presses against the plate member. Is preferable. According to such a manufacturing method, while the plate member is sandwiched between the adjacent sheet-like fiber structures, the tip of the convex portion presses against the plate member to suppress the displacement of the plate member. Thereby, when integrating a plurality of sheet-like fiber structures in a state where the plate member is sandwiched between adjacent sheet-like fiber structures, the plate member can be held at a predetermined set position. Become.

According to the first aspect of the present invention, since the cushion body is molded and the plate member is disposed in the cushion body at the same time, the number of steps is reduced, and a cushion body that can be easily manufactured is realized. .
According to the invention of claim 2, when integrating a plurality of sheet-like fiber structures, the plate member can be favorably held at a predetermined position between adjacent sheet-like fiber structures.
According to the invention of claim 3, it is possible to easily dispose the attitude regulating plate in the cushion body of the cushion body constituting the seat back of the vehicle seat.
According to invention of Claim 4, it becomes possible to acquire the vehicle seat which has said effect.
According to the invention of claim 5, since the molding of the cushion main body and the arrangement of the plate member inside the cushion main body are simultaneously performed, the number of steps is reduced, and the cushion body can be easily manufactured.
According to the invention of claim 6, the sheet-like fiber structure and the plate member can be easily set at a predetermined set position with respect to one mold, and can be favorably held at the set position. It becomes possible.
According to the invention of claim 7, when integrating a plurality of sheet-like fiber structures in a state where the plate members are sandwiched between adjacent sheet-like fiber structures, the positional deviation of the plate members is suppressed, and the predetermined It is possible to hold the plate member at the set position.

1 is a schematic perspective view of a vehicle seat according to the present invention. It is a schematic perspective view of a cushion body and a mounting frame according to the present invention. It is a schematic cross section of the cushion body concerning the present invention. It is a schematic front view of the cushion body concerning the present invention. It is sectional drawing which shows a mode that a skin material is mounted | worn with the cushion body which concerns on this invention. FIG. 6 is a cross-sectional view corresponding to the line AA in FIG. 5. It is explanatory drawing of the manufacturing process of the sheet-like fiber structure which concerns on this invention. 1 is a schematic perspective view of a set of molds according to the present invention. It is explanatory drawing regarding the manufacturing method of the cushion body which concerns on this invention. It is a figure which shows the flow of a cushion body manufacturing process. It is a figure which shows the flow of a base material acquisition step. It is a figure which shows the flow of a base material setting step. It is the elements on larger scale of the mounting part of hanging parts.

  Hereinafter, an embodiment of the present invention (hereinafter, this embodiment) will be described with reference to the drawings.

  1 to 13 relate to the present embodiment, FIG. 1 is a schematic perspective view of a vehicle seat according to the present invention, FIG. 2 is a schematic perspective view of a cushion body and a mounting frame according to the present invention, FIG. Is a schematic cross-sectional view of the cushion body according to the present invention, FIG. 4 is a schematic front view of the cushion body according to the present invention, FIG. 5 is a cross-sectional view showing a state in which the skin material is attached to the cushion body according to the present invention, and FIG. 5 is a cross-sectional view corresponding to the line AA in FIG. 5, FIG. 7 is an explanatory view of the manufacturing process of the sheet-like fiber structure according to the present invention, FIG. 8 is a schematic perspective view of a set of molds according to the present invention FIG. 10 is a diagram illustrating a flow of a cushion body manufacturing process, FIG. 11 is a diagram illustrating a flow of a base material acquisition step, and FIG. 12 is a flow of a base material setting step. FIG. 13 is a part of the mounting part of the suspended part It is a large figure.

  In the following description, the front-rear direction of the cushion body 10 (or the cushion body 100) is a direction corresponding to the thickness direction of the cushion body 10 (or the cushion body 100), and an occupant is in the vehicle seat S. When seated, the surface on the side that supports the back of the occupant is the front surface of the cushion body 10 (cushion body 100), and the opposite surface is the rear surface.

<< Overview of cushion body and vehicle seat >>
First, an outline of a cushion body 10 according to the present embodiment and a vehicle seat S using the cushion body 10 will be described with reference to FIGS.
The cushion body 10 according to the present embodiment is used as a component of the vehicle seat S illustrated in FIG. 1, and specifically, constitutes a seat back S1 of the vehicle seat. The seat back S <b> 1 includes a cushion body 10, a seat back frame 20 as an attachment frame, and a skin material 11 that covers the cushion body 10 and the seat back frame 20 as main components.

  The cushion body 10 is attached to the seat back frame 20 in a state of being disposed at the position shown in FIG. 2, so that the back of the occupant seated on the vehicle seat S is supported from behind (in other words, FIG. 2). The position of the cushion body 10 illustrated in FIG. 2 is a position where the back of the occupant seated on the vehicle seat S can be supported. The cushion body 10 is fastened and attached to the seat back frame 20 by an attachment wire 120 as a linear member.

  The schematic configuration of the cushion body 10 will be described. Main components of the cushion body 10 are a cushion main body 100, a posture regulating plate 110, the above-described attachment wire 120, and a suspended part 130 as shown in FIG. .

  The cushion main body 100 is a main part of the cushion body 10, and is formed by integrating steam by spraying a plurality of (four in the present embodiment) laminated sheet-like fiber structures 13, 14, 15, and 16. . The cushion main body 100 has an appearance shown in FIG. 4, for example, and the inner side portion 102 located on the inner side of the edge portion 101 is somewhat rearward with respect to the edge portion 101 located on both ends in the width direction of the cushion main body 100. It is overhanging.

  Further, a groove portion 103 that is recessed toward the rear side is provided at a predetermined position on the front surface of the cushion main body 100 (for example, a boundary position between the edge portion 101 and the inner portion 102). The groove 103 is formed to suspend the skin material 11 covering the cushion body 10 from the front of the cushion body 10.

  The posture regulating plate 110 is a resin plate member disposed in the cushion main body 100 (more specifically, the inner portion 102), and an occupant seated on the vehicle seat S droops into the seat back S1 on the back side. This is for regulating the posture of the occupant when it is hung.

  The attachment wire 120 is attached to one end surface (specifically, the rear surface) in the thickness direction of the posture regulating plate 110, and penetrates the cushion body 100 and protrudes from the rear surface of the cushion body 100. That is, a through-hole for allowing the attachment wire 120 to pass is formed in a portion of the cushion main body 100 located on the rear side of the posture regulating plate 110.

  In the present embodiment, two attachment wires 120 are provided side by side in the height direction of the posture regulating plate 110 at each of both ends in the width direction of the posture regulating plate 110. That is, in the present embodiment, a total of four attachment wires 120 are attached to the attitude regulating plate 110. However, the number of attachment wires 120 is not limited to four and can be changed to an arbitrary number.

  The suspended component 130 is a linear member that holds the skin material 11 introduced into the groove 103 and suspends the skin material 11 from the cushion body 100. The suspended component 130 extends along the groove 103 described above, and is disposed in the cushion body 100 with a part thereof exposed from the groove 103. Then, the skin material 11 is suspended by hooking the skin material 11 introduced into the groove 103 via a metal fitting (specifically, a C ring 11d described later) or the like on the exposed part of the suspension component 130. It is hung on the part 130.

  Next, a procedure for assembling the vehicle seat S using the cushion body 10 will be described. First, the cushion body 10 having the above-described configuration is manufactured by a manufacturing method described later. After completion of the cushion body 10, the tip end portion of the mounting wire 120 protruding from the rear surface of the cushion body 10 is locked to a locking portion 21a provided on the side portion 21 of the seat back frame 20 (see FIG. 2). As a result, the cushion body 10 is fastened to the seat back frame 20 in a state where the cushion body 10 is disposed at a predetermined position (specifically, the position shown in FIG. 2).

  After the fastening of the cushion body 10 to the seat back frame 20 is completed, the skin material 11 is suspended from the cushion body 10. Here, the structure for suspending the skin material 11 is demonstrated, referring FIG.5 and FIG.6.

  In the state where the decorative portion (front side) is bonded to the skin material 11, the end portion is stitched together by a stitching portion 11e, and a hanging cloth 11a is further stitched to the stitching portion 11e. Yes. The suspension cloth 11 a is a member that is disposed along the extending direction of the groove portion 103 of the cushion main body 100, and holds a long suspension wire 11 c that is disposed along the extending direction of the groove portion 103.

  The suspending wire 11c is held on the open end portion side of the suspending cloth 11a facing away from the stitching portion 11e. More specifically, the suspension cloth 11a is sewn so that the suspension cloth 11a is wound around the suspension wire 11c, thereby holding the suspension wire 11c. In addition, the hanging wire 11c is inserted through a ring-shaped portion of the hanging cloth 11a in a state where both ends thereof are bent so that the hanging wire 11c does not fall off the hanging cloth 11a.

  A plurality of ring through holes 11b are formed in the hanging cloth 11a, and a C ring 11d as a fixing member is inserted. On the other hand, the C ring 11 d is engaged with a suspended component 130 that is disposed in the cushion main body 100 and extends along the groove 103. That is, the C-ring 11d is hooked and engaged with the suspended component 130 (more specifically, the exposed portion of the suspended component 130) that is partially exposed through the opening of the groove 103.

  The C ring 11d is disposed so as to surround the suspension wire 11c and the suspension component 130, and finally the opening of the C ring 11d is closed using a tool or the like. As a result, the skin material 11 is suspended from the groove 103 formed in the cushion body 100. In addition, the structure which suspends the skin material 11 is not limited to this, As long as it is the structure by which the skin material 11 is suspended in the suspension component 130, it is good also as using methods other than the above.

  The seat back S1 is completed through the steps described above. Then, the vehicle seat S is completed by assembling the components (for example, the seating portion S2) other than the seat back S1 and the seat back S1 in the vehicle seat S.

<< Sheet Fiber Structure >>
Next, the sheet-like fiber structures 13, 14, 15, and 16 that form the base material of the cushion body 10 (more specifically, the cushion body 100) will be described.
The sheet-like fiber structures 13, 14, 15, and 16 are obtained by folding the web W, which is the raw fabric, into an accordion shape as shown in FIG. It is formed by cutting into a predetermined shape.

  In the web W, a heat-adhesive composite staple fiber having a melting point lower than that of the staple fiber and having a melting point of at least 120 ° C. is dispersed as an adhesive component in a matrix fiber composed of an aggregate of inelastic crimped staple fibers. It is a mixed one. More specifically, the web W according to this embodiment is 40 ° C. or higher than the melting point of the non-elastic polyester-based crimped short fiber as the non-elastic crimped short fiber and the polyester polymer constituting the non-elastic polyester-based crimped short fiber. A heat-adhesive composite staple fiber composed of a thermoplastic elastomer having a low melting point and an inelastic polyester is blended so that the fiber direction is mainly in the length direction. Furthermore, a three-dimensional fiber intersection is formed between the heat-adhesive composite short fibers and between the heat-adhesive composite short fibers and the inelastic polyester-based crimped short fibers by the heat treatment.

For example, it is preferable to use a hollow polyethylene terephthalate fiber having a single yarn fineness of 12 denier and a fiber length of 64 mm, which has three-dimensional crimps by anisotropic cooling, as the inelastic polyester crimped short fiber.
Non-elastic polyester-based crimped short fibers may be ordinary polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polypivalolactone or these Short fibers made of a copolymerized ester or a blend of these fibers, or composite fibers made of two or more of the above polymer components can be used. Among these short fibers, polyethylene terephthalate, polytrimethylene terephthalate or polybutylene terephthalate short fibers are preferable. Furthermore, latently crimped fibers comprising two types of polyethylene terephthalate, polytrimethylene terephthalate, or combinations thereof, which are different from each other in intrinsic viscosity, and having crimped microcrimps by heat treatment or the like can also be used.

  Moreover, the cross-sectional shape of the short fiber may be circular, flat, irregular, or hollow. The thickness of the short fiber is preferably in the range of 2 to 200 denier, particularly 6 to 100 denier. When the thickness of the short fiber is small, the softness is improved, but the elasticity of the cushion body is often lowered. On the other hand, when the thickness of the short fiber is too large, the handleability, particularly the web formability is deteriorated. In addition, the number of constituents becomes too small, and the number of intersections formed with the heat-adhesive composite short fibers decreases, which makes it difficult for the cushion body to exhibit elasticity, and at the same time, may decrease durability. Furthermore, the texture is too hard.

  Further, in this embodiment, as the heat-adhesive composite short fiber, a single-fiber fineness of 6 denier using a thermoplastic polyetherester elastomer having a melting point of 154 ° C. as a sheath component and a melting point of 230 ° C. polybutylene terephthalate as a core component, A core / sheath type heat-fusible conjugate fiber having a fiber length of 51 mm (core / sheath ratio = 60/40: weight ratio) is preferably used.

  The heat-bondable composite short fiber is composed of a thermoplastic elastomer and an inelastic polyester. And what the former occupies at least 1/2 of the fiber surface is preferable. In terms of weight ratio, it is appropriate that the former and the latter are in the range of 30/70 to 70/30 as a composite ratio. The form of the heat-bondable composite short fiber may be either side-by-side or sheath-core type, but the latter is preferred. In this sheath-core type, inelastic polyester is the core, but this core may be concentric or eccentric. In particular, an eccentric type is more preferable because coiled elastic crimps are developed.

  As the thermoplastic elastomer, a polyurethane elastomer or a polyester elastomer is preferable, and the latter is particularly suitable. Examples of polyurethane elastomers include low melting point polyols having a molecular weight of about 500 to 6000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates having a molecular weight of 500 or less, such as p, p-diphenylmethane diisocyanate, By reaction of diisocyanate, isophorone diisocyanate, hydrogenated diphenylmethane diisocyanate, xylylene diisocyanate, 2,6-diisocyanate methylcaproate, hexamethylene diisocyanate and the like with a chain extender having a molecular weight of 500 or less, such as glycol, amino alcohol or triol. The resulting polymer. Among these polymers, particularly preferred are polyurethanes using polytetramethylene glycol, poly-ε-caprolactone or polybutylene adipate as a polyol. In this case, p, p'-diphenylmethane diisocyanate is suitable as the organic diisocyanate. As the chain extender, p, p 'bishydroxyethoxybenzene and 1,4-butanediol are suitable.

  On the other hand, as a polyester-based elastomer, a polyetherester block copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically, terephthalic acid, isophthalic acid , Aromatic dicarboxylic acids such as phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, diphenoxyethanedicarboxylic acid, sodium 3-sulfoisophthalate 1,4-cyclohexanedicarboxylic acid and other alicyclic dicarboxylic acids, succinic acid, oxalic acid, adipic acid, sebacic acid, dodecanedioic acid, dimer acid and other aliphatic dicarboxylic acids or ester-forming derivatives thereof. At least one of the dicarboxylic acids 1,4-butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, neopentyl glycol, decamethylene glycol and other aliphatic diols, or 1,1-cyclohexanedimethanol, At least one diol component selected from alicyclic diols such as 1,4-cyclohexanedimethanol and tricyclodecanedimethanol, and ester-forming derivatives thereof, and an average molecular weight of about 400 to 5,000, Polyethylene glycol, poly (1,2- and 1,3-propylene oxide) glycol, poly (tetramethylene oxide) glycol, copolymers of ethylene oxide and propylene oxide, ethylene oxide and tet Of the poly (Alexander oxide) glycol and copolymers of hydrofuran is a terpolymer composed of at least one.

  However, a block copolymer polyether polyester having polybutylene terephthalate as a hard segment and polyoxybutylene glycol as a soft segment is preferable from the viewpoints of adhesiveness, temperature characteristics, and strength with a non-elastic polyester crimped short fiber. In this case, the polyester portion constituting the hard segment is a main acid component terephthalic acid and a polybutylene terephthalate whose main diol component is a butylene glycol component. Of course, part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or oxycarboxylic acid component, and part of the glycol component (usually 30 mol% or less) is also butylene. It may be substituted with a dioxy component other than the glycol component.

  Moreover, the polyether part which comprises a soft segment may be the polyether substituted by dioxy components other than butylene glycol. In the polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, colorants, and other various improving agents may be blended as necessary.

  The degree of polymerization of the polyester elastomer is preferably in the range of 0.8 to 1.7 dl / g, particularly 0.9 to 1.5 dl / g in terms of intrinsic viscosity. When this intrinsic viscosity is too low, the heat fixing point formed with the inelastic polyester-based crimped short fibers constituting the matrix tends to be broken. On the other hand, if the viscosity is too high, it becomes difficult to form spindle-shaped nodes during heat sealing.

  As a basic characteristic of the thermoplastic elastomer, the elongation at break is preferably 500% or more, and more preferably 800% or more. If the elongation is too low, when the cushion body 10 is compressed and the deformation reaches the heat fixing point, the bond at this portion is easily broken.

On the other hand, the 300% elongation stress of the thermoplastic elastomer is preferably 0.8 kg / mm ² or less, more preferably 0.8 kg / mm ² . If this stress is too large, the heat fixing point is difficult to disperse the force applied to the cushion body 10, and when the cushion body 10 is compressed, the heat fixing point may be destroyed by the force, or Even if not, the non-elastic polyester-based crimped short fibers constituting the matrix may be distorted or crimped.

  The 300% elongation recovery rate of the thermoplastic elastomer is preferably 60% or more, and more preferably 70% or more. If this elongation recovery rate is low, even if the cushion body 10 is compressed and the heat fixing point is deformed, it may be difficult to return to the original state. These thermoplastic elastomers have a lower melting point than the polymer constituting the inelastic polyester-based crimped short fibers, and the crimps of the crimped short fibers are thermally reduced during the fusing process for forming the heat fixing point. It is necessary not to let it. In this sense, the melting point is preferably 40 ° C. or more, particularly 60 ° C. or more lower than the melting point of the polymer constituting the short fiber. The melting point of such a thermoplastic elastomer can be set to a temperature in the range of 120 to 220 ° C., for example.

  If this difference in melting point is less than 40 ° C., the heat treatment temperature described below during the fusing process becomes too high, causing crimping of the inelastic polyester-based crimped short fibers, and the mechanical properties of the crimped short fibers. The characteristic is deteriorated. When the melting point of a thermoplastic elastomer is not clearly observed, the melting point alternates with a softening point.

  On the other hand, as the inelastic polyester used as the counterpart component of the thermoplastic elastomer of the composite fiber, a polyester polymer constituting a crimped short fiber forming a matrix as described above is employed. Polyethylene terephthalate, polytrimethylene terephthalate, and polybutylene terephthalate are more preferably employed.

The above-mentioned composite fiber is dispersed and mixed in a range of 20 to 100%, preferably 30 to 80%, based on the weight of the web.
In the web of this embodiment, the heat-adhesive composite staple fiber as the binder fiber and the non-elastic crimped staple fiber as the main fiber are mixed in a weight ratio of 60:40.

  If the dispersion / mixing rate of the composite fiber is too low, the number of heat fixing points may be reduced, and the cushion body 10 may be easily deformed, and the elasticity, rebound, and durability may be reduced. Moreover, there is a possibility that cracks in the mountains (between the convex portions formed continuously) arranged on the surface of the cushion body 10 may also occur.

In the present embodiment, inelastic polyester short fibers and heat-bondable composite short fibers are blended at a weight ratio of 40:60, passed through a roller card, and formed into a web having a basis weight of 20 g / m ^2. It is preferable.

  With respect to the total number per unit volume of the fibers X facing in the length direction (continuous direction) and the fibers Y facing in the lateral direction (width direction of the web W) in the continuous web, the web of the present embodiment. As described above, W is formed so that the relative proportion of the fibers oriented in the length direction is larger than that of the fibers oriented in the lateral direction. That is, the web W of the present embodiment is formed so as to satisfy the relationship of X ≧ 3Y / 2, preferably X ≧ 2Y per unit volume.

Here, the fiber oriented in the length direction of the web W is a fiber in which the angle θ in the length direction of the fiber with respect to the length direction of the web W satisfies the condition of 0 ° ≦ θ ≦ 45 °, The fiber oriented in the direction (web width direction) is a fiber satisfying θ satisfying 45 ° <θ ≦ 90 °.
Moreover, also about the direction of the fiber which comprises the sheet-like fiber structure 13,14,15,16, it follows the thickness direction of the sheet-like fiber structure 13,14,15,16 and a direction perpendicular | vertical to a thickness direction. The direction means one in a range of ± 45 ° with respect to these directions.

The direction in which each fiber faces was observed by extracting a random part in the surface layer part and inner layer part of the web W, and observing with a transmission optical microscope.
The web has a thickness of 5 mm or more, preferably 10 mm or more, and more preferably 20 mm or more. Usually, the thickness is about 5 to 150 mm.

  The web W formed mainly with the fibers along the length direction is folded like an accordion so as to have a predetermined density and a desired thickness as a structure, After forming a three-dimensional fiber intersection between the elastic polyester crimped short fiber and the composite fiber, heat treatment is performed at a temperature lower than the melting point of the polyester polymer and higher by 10 to 80 ° C. than the melting point (or flow starting point) of the thermoplastic elastomer. By doing so, the elastomer component is heat-sealed at the fiber intersection, and a flexible heat fixing point is formed.

  Specifically, as shown in FIG. 7, the drive roller 51 pushes the web W into the hot-air suction heat treatment machine 52 to fold it into an accordion shape, and heat treatment is performed at about 190 ° C. for several minutes in a heat treatment furnace. By wearing, sheet-like fiber structures 13, 14, 15, and 16 having appropriate thicknesses are formed.

In the sheet-like fiber structures 13, 14, 15, and 16 formed in this manner, the fixing points that are heat-sealed in a state where the heat-adhesive composite short fibers intersect with each other, and the heat-adhesive composite short fibers In this state, the fixing points that are heat-sealed in a state where the inelastic crimped short fibers intersect with each other are scattered.
The density of the sheet-like fiber structures 13, 14, 15, 16 is preferably in the range of 0.015 to 0.20 g / cm ³ , because cushioning properties, air permeability, and elasticity can be appropriately expressed. .

  By folding the web W formed so that the fibers are along the length direction, the sheet-like fiber structures 13, 14, 15, and 16 are thicker than the fibers facing the thickness direction. More than the fibers facing in the direction perpendicular to the direction, the fiber direction is mainly parallel to the thickness direction. That is, in the sheet-like fiber structure 13, 14, 15, 16 of this embodiment, the total number of fibers arranged along the thickness direction per unit volume is α, and the direction perpendicular to the thickness direction When the total number of fibers arranged along β is β, α ≧ 3β / 2, preferably α ≧ 2β is satisfied.

<< Cushion body manufacturing method >>
Below, the manufacturing method of the cushion body 10 which concerns on this embodiment is demonstrated.
First, the manufacturing procedure of the cushion body 10 will be briefly described. When the cushion body 10 is manufactured, a base material for manufacturing the cushion body 10 is acquired. Specifically, the above-described sheet-like fiber structures 13, 14, 15, 16, the attitude regulating plate 110, the attachment wire 120, and the hanging part 130 are prepared. In this embodiment, as the attitude | position control plate 110, what attached the attachment wire 120 beforehand to the rear surface is prepared. That is, in the present embodiment, the posture regulating plate 110 and the attachment wire 120 are ASSY (assy) and are handled as one component. Thus, in this embodiment, since several components are ASSY, handling becomes easy compared with the case where it isolate | separates as an individual component.

  As described above, the plurality of sheet-like fiber structures 13, 14, 15, and 16 as the base material of the cushion body 10 are integrally formed by spraying steam in a stacked state so as to form the cushion body 100. Become.

  More specifically, a plurality of sheet-like fiber structures 13, 14, 15, 16 are arranged between the upper mold 30 and the lower mold 40 as a set of molds that can be combined with each other. Then, the sheet-like fiber structures 13, 14, 15, and 16 stacked between the molds are pressed (clamped) so as to have a predetermined thickness and shape by two molds (upper mold 30 and lower mold 40). On the other hand, steam is blown to the plurality of sheet-like fiber structures 13, 14, 15, 16 through innumerable steam holes 31, 41 (see FIG. 8) formed on the mold surfaces of the molds 30, 40. Thereby, the fibers in the plurality of sheet-like fiber structures 13, 14, 15, 16 between the molds are heat-sealed, and the sheet-like fiber structures 13, 14, 15, 16 are integrated. .

  Here, the upper mold 30 and the lower mold 40 have the appearance shown in FIG. 8 and are made of a material having mechanical strength that can withstand high-pressure steam molding. In addition, as a material of each type | mold 30 and 40, the thing formed with resin using metals, such as iron, steel, and aluminum, glass fiber, and carbon fiber, a synthetic resin, etc. are mentioned, for example.

  In the present embodiment, the upper mold 30 is formed with a set hole 32 for setting the sheet-like fiber structure 13 and the posture regulating plate 110. The set hole 32 has a general hole shape (for example, a circular hole) or a slit shape, and may be provided separately from the vapor hole 31 described above, One of these may be used as the set hole 32.

  On the other hand, in the present embodiment, as described above, in the cushion body 10 as a finished product, the posture regulating plate 110 (more specifically, the mounting wire 120 and the posture regulating plate 110 made ASSY), and the suspended component 130 is disposed in the cushion body 100. In order to realize such a configuration, in the present embodiment, when the plurality of sheet-like fiber structures 13, 14, 15, 16 are arranged between the molds, at the same time, the posture regulating plate 110 and the suspended component 130 are disposed. It is sandwiched between the sheet-like fiber structures. When the plurality of sheet-like fiber structures 13, 14, 15, 16 are integrated, steam is sprayed in a state where the posture regulating plate 110 and the suspended component 130 are sandwiched between the sheet-like fiber structures. .

  More specifically, in the present embodiment, as shown in FIG. 9, the sheet-like fiber structure 13, the posture regulating plate 110, the sheet-like fiber structure 14, the suspended component 130, and the sheet-like fiber structure are viewed from above. 15 and the sheet-like fiber structure 16 are laminated in this order. Then, steam is blown in a state where these laminates are sandwiched between the upper mold 30 and the lower mold 40.

  Here, among the plurality of sheet-like fiber structures 13, 14, 15, 16, two sheet-like fiber structures adjacent to each other, and the sheet-like fiber structures 13, 14 sandwiching the attitude regulating plate 110 therebetween. Corresponds to the adjacent sheet-like fiber structure of the present invention. However, the combination of the adjacent sheet-like fiber structures is not limited to the sheet-like fiber structures 13 and 14 and may be other combinations.

  According to the manufacturing method as described above, in this embodiment, the molding of the cushion body 100 and the placement of the posture regulating plate 110 inside the cushion body 100 are performed at the same time. As a result, the number of processes is increased. Thus, the cushion body 10 can be easily manufactured. In other words, it can be said that the cushion body 10 according to the present embodiment is a cushion body that can be easily manufactured by reducing the number of steps in the manufacturing process.

  Next, the flow of the process (manufacturing process) which manufactures the cushion body 10 is explained in full detail about the manufacturing procedure of the cushion body 10. FIG. As shown in FIG. 10, the manufacturing process of the cushion body 10 includes a base material acquisition step S001, a base material setting step S002, a mold combination step S003, and a high-pressure steam molding step S004. Hereinafter, steps S001 to S004 will be described step by step.

<Base material acquisition step>
The base material acquisition step S001 is a step of preparing the sheet-like fiber structures 13, 14, 15, 16 as the base material of the cushion body 10, the posture regulating plate 110, the attachment wire 120, and the suspended component 130. is there. That is, this step S001 is comprised by the sheet-like fiber structure acquisition process S011, the attitude | position control plate acquisition process S012, and the suspended component acquisition process S013, as shown in FIG.

  In the sheet-like fiber structure acquisition step S011, the sheet-like fiber structures 13, 14, 15, and 16 having a predetermined shape and a predetermined thickness are formed using the web W described above as an original fabric. The sheet-like fiber structure 13 forms a portion that is located on the rearmost side when the cushion main body 100 is formed, is formed relatively wide, and more specifically, has a width that is longer than the width of the attitude regulating plate 110. Is formed.

  Note that, as described above, the sheet-like fiber structure 13 includes the posture regulating plate 110 in the direction in which the plurality of sheet-like fiber structures 13, 14, 15, 16 are stacked (in other words, the front-rear direction of the cushion body 100). Adjacent to each other. That is, the sheet-like fiber structure 13 is one end side (the side on which the attachment wire 120 is provided) in the direction in which the plurality of sheet-like fiber structures 13, 14, 15, and 16 are stacked as viewed from the posture regulation plate 110. It corresponds to a 1st sheet-like fiber structure.

  Further, the sheet-like fiber structure 13 is formed with a through-hole 13a through which the attachment wire 120 attached to the rear surface of the attitude regulating plate 110 is passed. The through hole 13a penetrates the sheet-like fiber structure 13 in the thickness direction, and when the sheet-like fiber structure 13 is overlaid on the rear surface of the posture regulating plate 110 in the base material setting step S002 which is a subsequent step. The attachment wire 120 is passed through. Thereby, the attitude | position control plate 110 comes to be positioned with respect to the sheet-like fiber structure 13.

  The sheet-like fiber structures 14 and 15 form a central part in the front-rear direction (thickness direction) of the cushion body 100 and are formed to be somewhat thinner than the sheet-like fiber structure 13 and the sheet-like fiber structure 16. The sheet-like fiber structure 16 is the frontmost portion when the cushion body 100 is formed, and is formed to be the widest among the four sheet-like fiber structures 13, 14, 15, 16.

  The sheet-like fiber structures 14, 15, 16 are formed with through holes 14 a, 15 a, 16 a having the same shape. Then, in the subsequent base material setting step S002, the sheet-like fiber structures 14, 15, and 16 are laminated so that these through holes 14a, 15a, and 16a are all in communication.

  Furthermore, about the sheet-like fiber structures 15 and 16, other through-holes 15b and 16b are formed in a portion that becomes the above-described groove portion 103 when the cushion main body 100 is formed, and in the base material setting step S002 When the sheet-like fiber structures 14, 15, and 16 are laminated, the other through holes 15b and 16b communicate with each other. When the cushion main body 100 is finally completed, the other through holes 15b and 16b form the groove portion 103 of the cushion main body 100.

  The sheet-like fiber structures 14, 15, 16 are positioned with the posture regulating plate 110 in between in the direction in which the plurality of sheet-like fiber structures 13, 14, 15, 16 are stacked. It is arranged on the opposite side to the side. That is, the sheet-like fiber structures 14, 15, and 16 are positioned on the other end side in the direction in which the plurality of sheet-like fiber structures 13, 14, 15, and 16 are stacked as viewed from the attitude regulating plate 110. This corresponds to the second sheet-like fiber structure.

  In the posture regulation plate acquisition step S012, the attachment wire 120 is attached to the rear surface of the posture restriction plate 110, and an ASSY component in which the attachment wire 120 and the posture restriction plate 110 are integrated is obtained. In other words, the posture restriction plate acquisition step S012 is a step of attaching the attachment wire 120 to the rear surface of the posture restriction plate 110. Here, in order to attach the attachment wire 120 to the rear surface of the posture regulating plate 110, in addition to joining the mounting wire 120 to the rear surface of the posture regulating plate 110, the mounting wire 120 is made gold during injection molding of the posture regulating plate 110. Incorporating into the mold and molding the posture regulating plate 110 integrally with the mounting wire 120 is also included.

  In the suspended component acquisition step S013, a steel insert wire is acquired as the suspended component 130. In the present embodiment, an insert wire bent in a substantially U-shape is acquired as the suspended component 130. However, the material of the suspended component 130 is not limited to steel, and other materials may be used as long as the C ring 11d is hooked.

<Base material set step>
The base material setting step S002 is a step of setting the member acquired in the base material acquisition step S001, which is the previous step, to the molds 30 and 40. As shown in FIG. 12, this step S002 includes a first setting step S021 for setting the base material on one mold (specifically, the upper mold 30) and the other mold (specifically, the lower mold 40). ) And a second setting step S022 for setting the base material.

  In the first setting step S021, the sheet-like fiber structure 13 as the first sheet-like fiber structure and the posture regulating plate 110 and the attachment wire 120 integrated as ASSY parts are set in the upper mold 30. Here, as described above, the sheet-like fiber structure 13 is a sheet-like fiber structure on the same side as the attachment wire 120 when viewed from the attitude regulating plate 110 sandwiched between adjacent sheet-like fiber structures. Corresponds to the body. Accordingly, the first setting step S021 includes the sheet-like fiber structure 13 on the same side as the attachment wire 120 and the attachment wire 120 when viewed from the posture regulating plate 110 sandwiched between adjacent sheet-like fiber structures. This corresponds to the step of setting the posture regulating plate 110 to which the is attached to the upper mold 30 which is one of the molds.

  More specifically, the sheet-like fiber structure 13 is stacked on the rear surface with the rear surface of the attitude regulating plate 110 to which the attachment wire 120 is attached facing upward, and the upper mold 30 is placed on the sheet-like fiber structure 13. And the posture regulating plate 110 and the sheet-like fiber structure 13 are set on the upper mold 30 (see FIG. 9). At this time, the sheet-like fiber structure 13 is overlapped on the rear surface of the posture regulating plate 110 through the through hole 13 a formed in the sheet-like fiber structure 13. Thereby, the attitude | position control plate 110 comes to be positioned with respect to the sheet-like fiber structure 13.

  Further, in the present embodiment, a set hole 32 is provided in the upper mold 30, and a portion of the attachment wire 120 protruding from the through hole 13 a is passed through the set hole 32. That is, when setting the sheet-like fiber structure 13, the posture regulating plate 110, and the attachment wire 120 to the upper mold 30, the attachment wire 120 is passed through the through hole 13a of the sheet-like fiber structure 13, Further, it passes through the set hole 32 of the upper mold 30.

  In the present embodiment, the attachment wire 120 is bent at the midway position, and the attachment wire 120 is passed through the set hole 32 until the bent portion 121 passes through the set hole 32. Then, the sheet-like fiber structure 13, the posture regulating plate 110, and the attachment wire 120 are set on the upper die 30 by hooking the bent portion 121 on the portion located at the edge of the set hole 32 of the upper die 30. It becomes like this.

  As described above, in the present embodiment, the attachment wire 120 is passed through the through hole 13 a and the set hole 32, whereby the sheet-like fiber structure 13 and the posture regulating plate 110 are placed in a predetermined set position with respect to the upper mold 30. Can be easily set, and can be satisfactorily held at the predetermined set position.

  In the second setting step S022, the sheet-like fiber structures 14, 15, 16 as the second sheet-like fiber structure are set in the lower mold 40. Here, as described above, the sheet-like fiber structures 14, 15, and 16 have through holes 14 a, 15 a, and 16 a having the same shape, and are laminated so that all the through holes 14 a, 15 a, and 16 a communicate with each other. Is done. On the other hand, on the surface of the lower mold 40 (the surface on the side on which the sheet-like fiber structures 14, 15, 16 are set), a sheet pressing portion 42 as a convex portion is erected.

  Then, by fitting the sheet pressing portion 42 into the communicating through holes 14a, 15a, 16a, the sheet-like fiber structures 14, 15, 16 are set in the lower mold 40, and the lower mold 40, each of the sheet-like fiber structures 14, 15, and 16 is favorably held at a predetermined set position. In the state where the sheet-like fiber structures 14, 15, 16 are set in the lower mold 40, the front end portion of the sheet pressing portion 42 passes through the through holes 14 a, 15 a, 16 a and protrudes out of the holes. .

  Moreover, in this embodiment, when setting the sheet-like fiber structure 14,15,16 to the lower mold | type 40, the suspended component 130 is interposed between the sheet-like fiber structure 14,15, and a sheet-like fiber The suspended parts 130 are also set in the lower mold 40 together with the structures 14, 15, 16.

  Further, in the present embodiment, as described above, the sheet-like fiber structures 14, 15, and 16 are laminated so that all the through holes 14 a, 15 a, and 16 a communicate with each other. The other through holes 15b and 16b formed in the bodies 15 and 16 also communicate with each other.

  The suspended component 130 is disposed between the sheet-like fiber structures 14 and 15 with a part thereof facing the other through holes 15b and 16b. In this state, the sheet-like fiber structures 14 and 15 and 16 is set in the lower mold 40. Here, when the sheet-like fiber structures 14, 15, and 16 are set in the lower mold 40, a part of the surface of the lower mold 40 is raised with respect to the other through holes 15 b and 16 b that communicate with each other. The raised portion 44 comes to be fitted. At this time, as shown in FIG. 13, a part of the suspended component 130 facing the other through holes 15 b and 16 b is engaged with the raised portion 44.

  More specifically, the suspended component 130 has a substantially U-shape and includes a bent portion 131 that is bent substantially at a right angle. The bent portion 131 and the erected portion 132 provided between the bent portions 131 are portions of the suspended component 130 facing the other through holes 15b and 16b. Then, when the sheet-like fiber structures 14, 15, 16 are set in the lower mold 40, when the raised portion 44 is fitted into the other through holes 15 b, 16 b, the bent portion 131 of the suspended component 130 is raised. 44 is caught in the corner of 44. Thereby, in a state where the sheet-like fiber structures 14, 15, 16 are set in the lower mold 40, the suspended component 130 is also arranged at a predetermined position and is held at the position.

  As described above, in the present step S002, the first sheet-like material positioned on one end side in the stacking direction of the sheet-like fiber structures as viewed from the posture regulating plate 110 sandwiched between adjacent sheet-like fiber structures. The fiber structure is set on the upper die 30 together with the attitude regulating plate 110, and the second sheet-like fiber structure located on the other end side is set on the lower die 40.

<Mold combination step>
The mold combination step S003 is a combination of the upper mold 30 and the lower mold 40 on which the sheet-like fiber structures 13, 14, 15, 16 and the like are set in the previous step S002, and a plurality of sheet-like fiber structures are placed between the molds. 13, 14, 15, 16, the posture regulating plate 110 and the suspended component 130 are arranged. More specifically, in this step S003, the upper mold 30 on which the sheet-like fiber structure 13 and the posture regulating plate 110 are set is set, and the sheet-like fiber structures 14, 15, 16 and the suspended parts 130 are set. From the upper position of the lower mold 40, the lower mold 40 is brought close to the two molds 30 and 40.

  By such a combination of the molds 30 and 40, between the upper mold 30 and the lower mold 40, from above, the sheet-like fiber structure 13, the posture regulating plate 110, the sheet-like fiber structure 14, the suspended component 130, The sheet-like fiber structure 15 and the sheet-like fiber structure 16 are disposed, and these base materials are sandwiched between two molds 30 and 40 and compressed in the stacking direction. And said base material (especially sheet-like fiber structure 13, 14, 15, 16) is compression-molded so that it may become the shape which the type | molds 30 and 40 prescribe | regulate.

  In the present embodiment, when the molds 30 and 40 are combined, the front end portion of the sheet pressing portion 42 protruding from the through holes 14a, 15a, and 16a formed in the sheet-like fiber structures 14, 15, and 16 is subjected to posture regulation. It comes to be pressed against the front surface of the plate 110. In other words, in a state where the molds 30 and 40 are combined, the sheet-like fiber structure 13 and the posture regulating plate 110 are sandwiched between the sheet pressing portion 42 and the upper mold 30. Thereby, the positional deviation of the attitude | position regulation plate 110 comes to be controlled in subsequent processes.

<High-pressure steam molding step>
In the high pressure steam forming step S004, a plurality of sheet-like fiber structures 13, 14, 15 are formed by blowing steam between the molds in a state where the molds 30, 40 are combined and the base material of the cushion body 10 is disposed between the molds. , 16 are integrated to form the cushion body 10. In the present embodiment, since steam is blown in a state where the posture regulating plate 110 is sandwiched between the sheet-like fiber structures 13 and 14 (that is, adjacent sheet-like fiber structures), the formation of the cushion body 100 and the cushion body The posture regulating plate 110 is placed in the 100 at the same time. As a result, in this embodiment, the number of processes is reduced, and the cushion body 10 can be easily manufactured.

  Further, in the mold combination step S003 of the previous step, the molds 30 and 40 are combined so that the leading end portion of the sheet pressing portion 42 is pressed against the posture regulating plate 110. As a result, in the high-pressure steam forming step S004, the positional deviation of the posture regulating plate 110 is regulated, and even if the steam is blown between the molds in this step S004, the posture regulating plate 110 is set to a predetermined set position. It is possible to keep it. As a result, when the posture regulating plate 110 is arranged inside the cushion body 100, it can be arranged at an appropriate position.

  When the high-pressure steam molding step S004 is completed, the cushion body 10 is molded between the molds. After that, the molds 30 and 40 are separated and the cushion body 10 is taken out from between the molds. finish.

  If it demonstrates regarding the cushion body 10 manufactured through the step demonstrated above, the cushion main body 100 which is the component will be between the sheet-like fiber structures 13 and 14 (namely, adjacent sheet-like fiber structure). It is formed by integrating a plurality of sheet-like fiber structures 13, 14, 15, 16 with the posture regulating plate 110 sandwiched therebetween. As a result, as described above, the number of steps is reduced, and the cushion body 10 that can be easily manufactured is realized. Furthermore, if it is the vehicle seat S using the said cushion body 10, what has said effect will be implement | achieved.

<< Other Embodiments >>
In the above embodiment, the cushion body 10 of the present invention and the method for manufacturing the cushion body 10 have been described. However, the above embodiment is for facilitating the understanding of the present invention, and does not limit the present invention. The present invention can be changed and improved without departing from the gist thereof, and the present invention includes the equivalents thereof. Further, the material, arrangement position, shape, and the like of each member described above are merely examples for achieving the effects of the present invention, and do not limit the present invention.

  For example, in the above embodiment, the cushion body 100 is formed by stacking and integrating the four sheet-like fiber structures 13, 14, 15, and 16. However, the cushion body 100 is used as a base material of the cushion body 100. The number of sheet-like fiber structures is not limited to the above number, and may be any number as long as it is at least two. In the above embodiment, the plurality of sheet-like fiber structures 13, 14, 15, and 16 are integrated by spraying steam to thermally bond the fibers to each other, but the present invention is not limited to this. Instead, it may be integrated by other methods (for example, heating with a heater or pressure bonding with a press).

  In the above embodiment, the sheet-like fiber structures 13, 14, 15, and 16 are integrated only by heat fusion between the fibers, but the present invention is not limited to this, and the sheet-like fiber structure is not limited thereto. A hot-melt adhesive or the like is applied between the bodies, and the sheet-like fiber structure may be more strongly bonded.

  Moreover, in said embodiment, as an example of the plate member pinched | interposed between adjacent sheet-like fiber structures (adjacent sheet-like fiber structure) among sheet-like fiber structures 13, 14, 15, and 16, attitude | position The restriction plate 110 has been described as an example. That is, in the above-described embodiment, the method for easily disposing the posture regulating plate 110 inside the cushion main body 100 of the cushion body 10 constituting the seat back S1 of the vehicle seat S has been described. However, the plate member is not limited to the posture regulation plate 110, and may be a plate member for a purpose different from the posture regulation.

  Further, in the above embodiment, the sheet-like fiber structure 13 and the posture regulating plate 110 are attached to the upper mold 30 by passing the attachment wire 120 attached to the posture regulating plate 110 through the through hole 13 a and the set hole 32. I decided to set it. Thereby, it becomes possible to easily set the sheet-like fiber structure 13 and the posture regulating plate 110 at a predetermined setting position. In this respect, the above-described embodiment is preferable, but is not limited thereto. For example, the posture regulating plate 110 is attached to the sheet-like fiber structure 13 with an adhesive or the like, and the posture regulating plate 110 is The sheet-like fiber structure 13 in a pasted state may be set (fixed) to the upper mold 30.

  In the above embodiment, the cushion body 10 has been described by taking the seat back S1 of the vehicle seat S as an example. However, the present invention is not limited to this, and the cushion body 10 of the present invention is a vehicle. It is good also as being used for the seat cushion (namely, seating part S2) of the seat S for use. That is, the cushion body of the present invention can be used as a component of a vehicle seat cushion. That is, when manufacturing a cushion body for a seat cushion using a plurality of sheet-like fiber structures and plate members, two adjacent sheets are used when spraying and integrating the plurality of laminated sheet-like fiber structures. A plurality of sheet-like fiber structures may be integrated in a state where plate members are arranged between the fiber-like structures. Thereby, like the case of manufacturing the cushion body 10 for the seat back S1, the formation of the cushion body and the placement of the plate member inside the cushion body are performed at the same time, and the above cushion body is easily manufactured. It becomes possible to do. In addition, the plate member used for the cushion body for seat cushions receives a load in the state in which the passenger | crew's buttocks seated on the vehicle seat was mounted. In addition, the plate member used for the cushion body for the seat cushion is provided with an attachment wire in the same manner as that provided for the cushion body 10 for the seat back S1 (that is, the posture regulating plate 110), and the cushion body (Those integrated with the sheet-like fiber structure by blowing steam) are projected from the rear surface of the cushion body, and the cushion body for the seat cushion is attached to the seat cushion frame (not shown) by the attachment wire. It will be concluded.

  Moreover, in said embodiment, although the case using the cushion body 10 as a component of the vehicle seat S was mentioned as an example, the cushion body 10 of the present invention is a chair other than the vehicle seat S (for example, It can also be suitably used for office chairs, nursing chairs, massage chairs, various chairs such as sitting chairs).

10 cushion body, 11 skin material,
11a Hanging cloth, 11b Ring through hole,
11c Suspension wire, 11d C-ring, 11e Suture part,
13, 14, 15, 16 Sheet-like fiber structure,
13a through hole, 14a, 15a, 16a through hole,
15b, 16b other through holes,
20 seat back frame, 21 side part, 21a locking part,
30 upper molds, 31 steam holes, 32 set holes,
40 Lower mold, 41 Vapor hole,
42 sheet pressing part, 44 raised part,
51 driving roller, 52 hot air suction heat treatment machine,
100 cushion body, 101 edge, 102 inner side,
103 groove, 104 opening,
110 attitude control plate,
120 mounting wires, 121 bends,
130 suspended parts, 131 bent parts, 132 installation parts,
S vehicle seat, S1 seat back, S2 seating part,
W Web

Claims (7)

A cushion body formed by integrating a plurality of laminated sheet-like fiber structures; and
A cushion member having a plate member disposed in the cushion body,
The cushion body integrates the plurality of sheet-like fiber structures with the plate member sandwiched between two adjacent sheet-like fiber structures adjacent to each other among the plurality of sheet-like fiber structures. A cushion body characterized by being formed by the above. The cushion body is fastened to the mounting frame by a linear member,
The linear member is attached to one end surface in the thickness direction of the plate member,
Among the plurality of sheet-like fiber structures, the sheet-like fiber structure on the same side as the linear member when viewed from the plate member sandwiched between the adjacent sheet-like fiber structures, The cushion body according to claim 1, wherein a through hole for passing the linear member is formed. The cushion body constitutes a seat back of a vehicle seat,
The said plate member is an attitude | position regulation plate for regulating the attitude | position of the said passenger | crew when the passenger | crew who seated on the said vehicle seat leans on the said seat back on the back side. The cushion body as described in 2.   A vehicle seat comprising: the cushion body according to claim 3; and a skin material covering the cushion body. A cushion body having a cushion body formed by integrating a plurality of laminated sheet-like fiber structures, and a plate member disposed in the cushion body,
Disposing the plurality of sheet-like fiber structures between a set of molds that can be combined with each other;
Forming the cushion body by integrating the plurality of sheet-like fiber structures disposed between the set of molds, and
In the step of disposing the plurality of sheet-like fiber structures between the set of molds, the plate member is disposed between two adjacent sheet-like fiber structures adjacent to each other among the plurality of sheet-like fiber structures. Placing the plurality of sheet-like fiber structures between the pair of molds,
In the step of forming the cushion body, the plurality of sheet-like fiber structures are integrated in a state where the plate member is sandwiched between the adjacent sheet-like fiber structures. Attaching a linear member for fastening the cushion body to an attachment frame on one end face in the thickness direction of the plate member;
Of the plurality of sheet-like fiber structures, a sheet-like fiber structure on the same side as the linear member as viewed from the plate member sandwiched between the adjacent sheet-like fiber structures, and Setting the plate member to which the linear member is attached to one of the set of molds, and
In the step of setting the sheet-like fiber structure on the same side as the linear member and the plate member on which the linear member is attached to the one mold, the sheet-like fiber structure on the same side as the linear member The linear member is passed through a through hole formed in a fiber structure, and a portion of the linear member protruding from the through hole is passed through a set hole formed in the one mold. The method for manufacturing a cushion body according to claim 5. Positioned on one end side in the direction in which the plurality of sheet-like fiber structures are stacked, as viewed from the plate member sandwiched between the adjacent sheet-like fiber structures among the plurality of sheet-like fiber structures. The first sheet-like fiber structure to be set together with the plate member in one of the set of molds, and the second sheet-like fiber structure located on the other end is set in the other mold Have
When the first sheet-like fiber structure is set in the one mold together with the plate member, the plate member is positioned on the side opposite to the one mold as viewed from the first sheet-like fiber structure. As described above, the first sheet-like fiber structure is set in the one mold together with the plate member,
When setting the second sheet-like fiber structure in the other mold, the convex portion provided in the other mold is passed through a through hole formed in the second sheet-like fiber structure, Set the second sheet-like fiber structure in the other mold,
In the step of disposing the plurality of sheet-like fiber structures between the set of molds, the first sheet-like fiber structure and the plate member are set in the one mold and the second sheet-like fibers. Combining the other mold with the structure set,
The method of manufacturing a cushion body according to claim 5 or 6, wherein when the one mold and the other mold are combined, a tip of the convex portion protruding from the through hole presses against the plate member.

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