JP3637762B2 - Manufacturing method of seat cover - Google Patents

Manufacturing method of seat cover Download PDF

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Publication number
JP3637762B2
JP3637762B2 JP04221698A JP4221698A JP3637762B2 JP 3637762 B2 JP3637762 B2 JP 3637762B2 JP 04221698 A JP04221698 A JP 04221698A JP 4221698 A JP4221698 A JP 4221698A JP 3637762 B2 JP3637762 B2 JP 3637762B2
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Japan
Prior art keywords
fiber
fiber web
web layer
melting
skin material
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JPH11240090A (en
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一仁 亀崎
健二 末吉
正利 鈴木
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Toyota Boshoku Corp
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Toyota Boshoku Corp
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  • Seats For Vehicles (AREA)
  • Laminated Bodies (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
  • Nonwoven Fabrics (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、表皮材が起毛を有するファブリック地などのヒートセット時の熱圧により影響を受けやすい材料であっても色落ちや毛倒れがなく、また表皮材に繊維ウェブ層や接着層の凹凸が表れることがなく、表皮材を的確容易に繊維ウェブに接着できて外観品質に優れた自動車などのシートを容易に量産できるシートカバーの製造方法に関するものである。
【０００２】
【従来の技術】
自動車などのシートに用いられるシートカバーとして、最近では従来のポリウレタンフォームなどのプラスチックフォームの表面に表皮材が添着一体化された積層表皮材に換えて、低コストで廃棄公害上或いはリサイクリング上の問題もない主としてポリエステル繊維などの長繊維を絡合させた繊維ウェブ層をワディング材とし、これに接着層を介して表皮材を接着一体化したものが、例えば実開平５−１５８９９号公報や特開平４−３３２５９０号公報などにより種々提案されている。
【０００３】
このようなシートカバーを製造する方法として、前記繊維ウェブ層と接着層と表皮材を重ねて通気性を有する板状の加圧部材で所定厚みまで圧縮した状態とし、これに熱風を通過させて接着とヒートセット加工を行うのが従来から行われていたが、このようにして接着とヒートセット加工とを同時に行うと、熱風によって高温化された加圧部材が直接表皮材を押圧することとなり、表皮材の表面が熱影響を受け、特に表皮材が起毛を有するファブリック地であるときは、起毛が毛倒れしたり、白化現象が生じるなど外観品質が著しく損なわれるという問題点があった。そこで、本件出願人は熱風による加熱工程と冷却した加圧板による加圧圧縮工程とを分離して行い上記問題点を解消したシートカバーの製造方法を開発し、先に特願平８−２８７７０８号として出願した。ところが、ヒートセット温度を高くすると表皮材の色落ちが発生するため低めの温度で行う必要があり、繊維ウェブ層間の融着不足による強度低下が生じるという問題点があった。また、それに伴い厚み規制をすることができないという問題点や、表面が凸凹になって外観品質が低下するという問題点があった。
【０００４】
【発明が解決しようとする課題】
本発明は上記のような従来の問題点を解決して、ヒートセット加工時に表皮材の表面が熱影響を受けることがなくて色落ちがなく、また毛倒れや白化もなく外観品質に優れた製品を生産することができ、しかも優れた生産性を発揮して効率よく低コストで量産を行うことができるシートカバーの製造方法を提供することを目的として完成されたものである。
【０００５】
【課題を解決するための手段】
上記の課題を解決するためになされた本発明のシートカバーの製造方法は、高融点繊維と低融点繊維との混合繊維よりなる繊維ウェブ層の表面に熱溶融性の接着層を介して通気性のある表皮材を重ねたうえ前記接着層を熱風の通過により溶融させて表皮材を繊維ウェブ層に接着するとともに繊維ウェブ層をヒートセットするようにしたシートカバーの製造方法において、前記ヒートセットに先立ち繊維ウェブ層を低融点繊維の融点以上の熱風により加熱処理するプリヒートセットを施して低融点繊維が高融点繊維に融着した状態とし、これに表皮材を重ねた後、表皮材が色落ちを起こさない温度以下の熱風を供給してヒートセットを施して繊維ウェブ層の低融点繊維と熱溶融性の接着層とを溶融させ、次いで加圧板により加圧しながら冷却して繊維ウェブ層を所定厚みに圧縮するすることを特徴とするものである。
【０００６】
【発明の実施の形態】
以下、本発明の好ましい実施の形態を図１に示した製造工程説明図と、図２に示した本発明により得られたシートカバーの断面図を参考にしながら詳細に説明する。
図中、１は高融点繊維のフィラメント１ａと低融点繊維のフィラメント１ｂとの混合繊維よりなる繊維ウェブ層、２は耐熱性に優れた通気性のある表皮材、３は低融点繊維の肉薄ウェブ若しくはホットメルトウェブなどの前記低融点繊維の融点程度に加熱されると溶融して接着能が付与される接着層、４は必要に応じて繊維ウェブ層１の裏面に重ねられた裏基布である。なお、前記した混合繊維よりなる繊維ウェブ層１における高融点繊維のフィラメント１ａと低融点繊維のフィラメント１ｂとの混合割合は、通常では７：３〜９：１程度であり、また、目付け量は１００〜５００g/m2程度を普通とする。
【０００７】
前記した混合繊維よりなる繊維ウェブ層１の高融点繊維のフィラメント１ａとしては、例えば、ポリプロピレン系繊維、ポリエステル系繊維、ポリアミド系繊維などの融点が２００〜２４０℃で、２〜１３デニール程度のものが用いられ、一方、低融点繊維のフィラメント１ｂとしては、例えばポリエステル系繊維やポリプロピレン系繊維などの融点が１００〜１６０℃で、２〜６デニール程度のものが用いられる。なお、低融点繊維のフィラメント１ｂは全体が低融点のものではなく、ポリエステル系その他比較的高融点の樹脂からなる芯材の表面に融点が１００〜１６０℃のポリエステル樹脂やポリプロピレン樹脂等の低融点の樹脂で被覆した芯鞘繊維を使用することもできる。
【０００８】
一方、表皮材２としては、ポリエステル系繊維を素材としたファブリック地等の比較的高融点で且つ通気性を有し表面に起毛を有するものとしたとき、本発明は極めて有効である。また、接着層３としては、融点が１００〜１６０℃、目付け量が約１０〜５０g/m2で２〜６デニール程度の全融タイプの低融点繊維のフィラメントからなる肉薄ウェブや、ある程度の通気性を有するシートタイプのホットメルトウェブなどが用いられ、更にまた、裏基布４は一般にスパンボンド布と称されている高密度不織布構造よりなるもので、必要に応じてシートカバーの強度を向上させる目的で用いられる。
【０００９】
なお図１において、５はプリヒートセット室であり、後記するヒートセットに先立ち繊維ウェブ層１を低融点繊維の融点以上の熱風により加熱処理し、低融点繊維を高融点繊維に融着させて仮固着した状態とするものである。また、１０は前記プリヒートセットを施した繊維ウェブ層１に針刺加工を施すためのニードルパンチ機、１１はヒートセット室で、このヒートセット室１１は、加熱ゾーン１１ａと、冷却ゾーン１１ｂとが連続して形成されていてその内部に前記各ゾーンを通過するようにメッシュ金網などの通気性帯材をコンベヤベルトとした搬送用のベルトコンベヤ１３が設置されているとともに、冷却ゾーン１１ｂの内部には該ベルトコンベヤ１３に対応して上部側に加圧板１２が設置されている。この加圧板１２は、繊維ウェブ層を冷却処理しつつ所定厚みに圧縮するためのもので、図示のものにおいては、例えば、ステンレス鋼板などの金属板製のコンベヤベルトよりなるベルトコンベヤとされ、その内部に設けた上下一対の加圧ローラ等の加圧部材１４、１５により通過する被処理材料が加圧板１２とベルトコンベヤ１３との間に挟持されて加圧されるよう構成されている。
なお、前記加圧板１２はベルトコンベヤ１３と同様、メッシュ金網などの通気性帯材を用いることもでき、また、ベルトコンベヤでなく単なる板状の加圧部材とすることもできる。そして、該加圧板１２は冷却ゾーン１１ｂの内部に１０〜３０℃程度の冷風を送り込む図示しないファン等の一般的な冷却手段により３０℃以下の温度に調整され、この温度調整された冷却板１２によって冷却処理しつつ加圧圧縮できるよう構成されている。
【００１０】
次に、本発明のシートカバーの成形工程を図１を参照しつつ説明する。
先ず、繊維ウェブ層１の裏面に裏基布４が重ねられた状態でラインに送られて被処理材料が送られてくると、常法に従いニードルパンチ機１０によってペネ数が数十本程度に針刺加工され、これにより繊維ウェブ層１と裏基布４とが絡合一体化された積層体となる。続いて、この積層体はプリヒートセット室５で、後記するヒートセットに先立ち繊維ウェブ層１の低融点繊維のフィラメント１ｂのみが十分に溶融する温度である１２０〜１８０℃の熱風により加熱処理され、表面が溶融した低融点繊維のフィラメント１ｂが高融点繊維のフィラメント１ａとの接点において溶融・接着されて仮固着した状態となる。そして、このプリヒートセット室５における仮固着工程は、後記するヒートセット工程での表皮材２の色落ちを防止するためのもので、本発明の特徴的構成である。
【００１１】
次いで、プリヒートセットが施された繊維ウェブ層１の表面に接着層３を介し表皮材２が重ねられてヒートセット室１１に送り込まれ、ここで接着層３が溶融されて表皮材２が繊維ウェブ層１に接着されるとともにヒートセットされて製品となって送り出されるのであるが、ヒートセット室１１における接着およびヒートセット工程も本発明の特徴的構成である。
即ち、このヒートセット室１１の加熱ゾーン１１ａに被処理材料が送られてくると、このヒートセット室１１においては、前記高融点繊維のフィラメント１ａの融点以下で低融点繊維のフィラメント１ｂと接着層３の融点以上で、かつ表皮材２の色落ちが生じない温度である１２０〜１４０℃程度の熱風が表皮材２の表側から繊維ウェブ層１の裏側に向け供給されるようになっており、この熱風の供給によって低融点繊維のフィラメント１ｂと接着層３のみが溶融し、溶融した低融点繊維のフィラメント１ｂが高融点繊維のフィラメント１ａとの接点において接着可能な表面が溶融された状態となるとともに、繊維ウェブ層１と表皮材２とは溶融した接着層３によって接着可能な状態となる。この場合、表皮材２には、例えば、風速が０．５〜３m/s 程度の熱風の供給による風圧のみが作用しても、敢えて加圧部材により加圧されることはないので、起毛が加圧部材により加圧されて毛倒れするような現象が発生することはない。また、従来ヒートセット処理は接着強度のアップをねらって１５０〜１８０℃程度で行っていたが、本発明では前述のようにプリヒートセットを施してあるため、既に低融点繊維のフィラメント１ｂと高融点繊維のフィラメント１ａとは仮固着された状態であり、少なくとも接着層３の融点（例えば、約１１０℃）以上の温度で加熱処理すればよい。この結果、表皮材２の色落ちが完全に防止されることとなる。
【００１２】
次に、前記したように低融点繊維のフィラメント１ｂと接着層３とが溶融された状態でヒートセット室１１の冷却ゾーン１１ｂに被処理材料が送られてくると、この冷却ゾーン１１ｂにおいては３０℃以下に温度調節されている前記加圧板１２によって積極的に加圧される。このように低融点繊維のフィラメント１ｂと接着層３とが溶融された状態で冷却ゾーン１１ｂに送られた直後に加圧板１２による積極的な加圧を行うと、この加圧板１２による加圧で全体に圧縮圧力が分散されながら冷却が行われることとなるが、冷却初期に溶融状態にある繊維ウェブ層１の表面と接着層３とは表皮材２を介して加圧力が伝達されて平滑化されつつ表皮材２が接着され、これと同時に繊維ウェブ層全体に圧縮圧力が分散した状態で冷却されつつ繊維ウェブ層は所定厚みに圧縮される。そして、低融点繊維のフィラメント１ｂと接着層３の軟化点である７０〜９０℃まで冷却が進むと先に溶融した低融点繊維のフィラメント１ｂはこれと接触している高融点繊維のフィラメント１ａに融着する。なお、前記低融点繊維フィラメント１ｂとして芯鞘繊維フィラメントを用いた場合には、鞘部のみが融着し芯部は熱影響を全く受けず、このためより強度に優れた繊維ウェブ層１が得られることとなるので特に好ましい。
【００１３】
そして、この冷却ゾーン１１ｂにおいて最終的に１０〜３０℃の温度域まで冷却が進むと、軟化状態にあった低融点繊維のフィラメント１ｂと接着層３は共に完全冷却されて接着力が強化されるとともに、加圧部材１４、１５の作用でコンベヤベルト間に挟まれて所定の厚さに混合繊維ウェブ１が圧縮され、この圧縮状態でセットされるので繊維ウェブ１は所定の厚さに保持されることなる。この加圧時に表皮材２の表面は加圧板１２に接触するが、３０℃以下の低温下における加圧であるため、表皮材２の起毛に毛倒れ現象を発生させることや、表皮材２に白化現象を発生させることはなく、外観品質に優れた製品を生産できることとなり、また加圧板１２による全体に圧縮圧力が分散した状態での加圧であるので、接着強度も均一であり、しかも、表皮材２は溶融状態での加圧で平滑化されている繊維ウェブ１に平滑化された接着層３を介して接着されることとなるので、薄い表皮材であっても繊維ウェブ１の凹凸の影響を受けることがなく、表面が平滑な高品質な製品が得られることとなる。
【００１４】
【発明の効果】
本発明は以上の説明からも明らかなように、ヒートセット加工時に表皮材の表面が熱影響を受けることがなくて色落ちがなく、また毛倒れや白化もなく外観品質に優れた製品を生産することができ、しかも優れた生産性を発揮して効率よく低コストで量産を行うことができるものである。
よって本発明は従来の問題点を一掃したシートカバーの製造方法として、産業の発展に寄与するところは極めて大である。
【図面の簡単な説明】
【図１】本発明の実施の形態におけるシートカバーの成形工程を示す概略図である。
【図２】本発明により製造されたシートカバーの断面図である。
【符号の説明】
１ 繊維ウェブ層
1a 高融点繊維のフィラメント
1b 低融点繊維のフィラメント
２ 表皮材
３ 接着層
４ 裏基布
５ プリヒートセット室
10 ニードルパンチ機
11 ヒートセット室
11a 加熱ゾーン
11b 冷却ゾーン
12 加圧板[0001]
BACKGROUND OF THE INVENTION
The present invention does not cause discoloration or hair fall even if it is a material that is easily affected by heat pressure during heat setting, such as a fabric with raised skin, and the surface of the skin material is uneven in the fiber web layer and adhesive layer. The present invention relates to a method of manufacturing a seat cover that can easily mass-produce a sheet of an automobile or the like excellent in appearance quality by allowing a skin material to be adhered to a fiber web accurately and easily.
[0002]
[Prior art]
Recently, as a seat cover used for automobile seats, instead of a laminated skin material in which a skin material is attached and integrated on the surface of a conventional plastic foam, such as polyurethane foam, it is low cost and disposal pollution or recycling A fiber web layer in which long fibers such as polyester fibers are entangled without any problem is used as a wadding material, and a skin material is bonded and integrated through an adhesive layer, for example, Japanese Utility Model Laid-Open No. 5-15899 and Various proposals have been made in Japanese Laid-Open Patent Publication No. 4-332590.
[0003]
As a method of manufacturing such a seat cover, the fiber web layer, the adhesive layer, and the skin material are overlapped and compressed to a predetermined thickness with a plate-like pressure member having air permeability, and hot air is passed through this. Bonding and heat-set processing have been performed in the past, but when bonding and heat-set processing are performed at the same time, the pressure member heated by hot air directly presses the skin material. The surface of the skin material is affected by heat, and in particular, when the skin material is a fabric having raised hair, there is a problem that the appearance quality is remarkably impaired such as raising the hair falling or causing whitening. Accordingly, the present applicant has developed a method of manufacturing a seat cover that solves the above problems by separating the heating process using hot air and the pressure compression process using a cooled pressure plate, and previously described Japanese Patent Application No. 8-287708. As filed. However, when the heat set temperature is raised, the skin material is discolored, so it is necessary to carry out at a lower temperature, and there is a problem that the strength is lowered due to insufficient fusion between the fiber web layers. In addition, there is a problem that the thickness cannot be regulated and a problem that the appearance quality is deteriorated because the surface becomes uneven.
[0004]
[Problems to be solved by the invention]
The present invention solves the above-mentioned conventional problems, and the surface of the skin material is not affected by heat at the time of heat-set processing, does not lose color, and has excellent appearance quality without hair fall or whitening. The present invention has been completed for the purpose of providing a method of manufacturing a seat cover that can produce a product, and that can exhibit mass productivity and perform mass production efficiently and at low cost.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, the seat cover manufacturing method of the present invention is characterized in that the surface of a fiber web layer composed of mixed fibers of high-melting fibers and low-melting fibers is air-permeable through a heat-meltable adhesive layer. In the sheet cover manufacturing method in which the surface layer material is stacked and the adhesive layer is melted by passage of hot air to adhere the surface material to the fiber web layer and the fiber web layer is heat set. First, the fiber web layer is preheated with hot air having a melting point higher than that of the low-melting fiber so that the low-melting fiber is fused to the high-melting fiber. The hot web below the temperature that does not cause heat is supplied and heat set to melt the low melting point fiber of the fiber web layer and the heat-melting adhesive layer, and then cooled while pressing with a pressure plate It is characterized in that compressing the fiber web layer to a predetermined thickness.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the manufacturing process explanatory diagram shown in FIG. 1 and the sectional view of the seat cover obtained by the present invention shown in FIG.
In the figure, 1 is a fiber web layer made of mixed fibers of filaments 1a of high-melting fibers and filaments 1b of low-melting fibers, 2 is an air-permeable skin material excellent in heat resistance, and 3 is a thin web of low-melting fibers. Alternatively, an adhesive layer 4 that melts when heated to the melting point of the low-melting fiber, such as a hot-melt web, is provided with a backing base fabric that is superimposed on the back surface of the fiber web layer 1 as necessary. is there. In addition, the mixing ratio of the filament 1a of the high melting point fiber and the filament 1b of the low melting point fiber in the fiber web layer 1 made of the above-described mixed fiber is usually about 7: 3 to 9: 1, and the basis weight is About 100 to 500 g / m 2 is normal.
[0007]
As the filament 1a of the high melting point fiber of the fiber web layer 1 composed of the above-described mixed fiber, for example, a polypropylene fiber, a polyester fiber, a polyamide fiber or the like has a melting point of 200 to 240 ° C. and about 2 to 13 deniers. On the other hand, as the filament 1b of the low melting point fiber, for example, a polyester fiber or polypropylene fiber having a melting point of 100 to 160 ° C. and about 2 to 6 denier is used. In addition, the low melting point fiber filament 1b is not entirely low melting point, but has a low melting point such as polyester resin or polypropylene resin having a melting point of 100 to 160 ° C. on the surface of a core material made of polyester or other relatively high melting point resin. It is also possible to use a core-sheath fiber coated with the above resin.
[0008]
On the other hand, as the skin material 2, the present invention is extremely effective when it has a relatively high melting point, such as a fabric made of polyester fiber, has air permeability, and has raised surfaces. The adhesive layer 3 may be a thin web made of filaments of low melting point fibers of all melting type having a melting point of 100 to 160 ° C., a basis weight of about 10 to 50 g / m 2 and about 2 to 6 denier, Sheet-type hot-melt webs are used, and the back base fabric 4 is made of a high-density nonwoven fabric structure generally called a spunbond fabric, improving the strength of the seat cover as required. It is used for the purpose.
[0009]
In FIG. 1, reference numeral 5 denotes a preheat setting chamber. Prior to heat setting, which will be described later, the fiber web layer 1 is heat-treated with hot air having a melting point higher than that of the low melting point fiber, and the low melting point fiber is fused to the high melting point fiber. It is in a fixed state. Reference numeral 10 denotes a needle punching machine for performing a needle stab process on the fiber web layer 1 subjected to the preheat setting. Reference numeral 11 denotes a heat setting chamber. The heat setting chamber 11 includes a heating zone 11a and a cooling zone 11b. A belt conveyor 13 is provided which is formed continuously and has a breathable belt material such as a mesh wire mesh as a conveyor belt so as to pass through each of the zones, and in the cooling zone 11b. Corresponding to the belt conveyor 13, a pressure plate 12 is installed on the upper side. The pressure plate 12 is for compressing the fiber web layer to a predetermined thickness while cooling, and in the illustrated case, for example, a belt conveyor made of a conveyor belt made of a metal plate such as a stainless steel plate, A material to be processed that passes by pressure members 14 and 15 such as a pair of upper and lower pressure rollers provided inside is sandwiched between the pressure plate 12 and the belt conveyor 13 and pressed.
As with the belt conveyor 13, the pressure plate 12 can be made of a breathable belt such as a mesh wire mesh, or can be a simple plate-shaped pressure member instead of the belt conveyor. The pressure plate 12 is adjusted to a temperature of 30 ° C. or less by a general cooling means such as a fan (not shown) that feeds cold air of about 10 to 30 ° C. into the cooling zone 11b. Thus, the pressure compression can be performed while cooling.
[0010]
Next, the molding process of the seat cover of the present invention will be described with reference to FIG.
First, when the material to be treated is sent to the line in a state where the back base fabric 4 is overlapped on the back surface of the fiber web layer 1, the number of penets is reduced to about several tens by the needle punch machine 10 according to a conventional method. Needle stab processing is performed, whereby a laminated body in which the fiber web layer 1 and the backing base fabric 4 are intertwined and integrated is obtained. Subsequently, this laminate is heated in the preheat set chamber 5 with hot air of 120 to 180 ° C., which is a temperature at which only the filament 1b of the low-melting fiber of the fiber web layer 1 is sufficiently melted prior to heat setting to be described later, The filament 1b of the low-melting fiber whose surface is melted is melted and bonded at the contact point with the filament 1a of the high-melting fiber to be temporarily fixed. The temporary fixing process in the preheat setting chamber 5 is for preventing color fading of the skin material 2 in the heat setting process described later, and is a characteristic configuration of the present invention.
[0011]
Next, the skin material 2 is superimposed on the surface of the fiber web layer 1 subjected to the preheat setting via the adhesive layer 3 and fed into the heat setting chamber 11, where the adhesive layer 3 is melted and the skin material 2 becomes the fiber web. Although it adhere | attaches on the layer 1 and is heat-set, it is sent out as a product, The adhesion | attachment in the heat-set chamber 11 and a heat-set process are also the characteristic structures of this invention.
That is, when the material to be treated is sent to the heating zone 11a of the heat set chamber 11, the heat set chamber 11 has a low melting point filament 1b and an adhesive layer which are below the melting point of the high melting point filament 1a. Hot air of about 120 to 140 ° C., which is a temperature that is not lower than the melting point of 3 and does not cause color fading of the skin material 2, is supplied from the front side of the skin material 2 toward the back side of the fiber web layer 1, By supplying the hot air, only the low melting point fiber filament 1b and the adhesive layer 3 are melted, and the melted surface of the melted low melting point fiber filament 1b at the contact point with the high melting point fiber filament 1a is melted. At the same time, the fiber web layer 1 and the skin material 2 can be bonded together by the molten adhesive layer 3. In this case, for example, even if only the wind pressure due to the supply of hot air having a wind speed of about 0.5 to 3 m / s is applied to the skin material 2, it is not pressurized by the pressing member. There is no occurrence of a phenomenon that the hair falls due to being pressed by the pressing member. In addition, the conventional heat setting treatment was performed at about 150 to 180 ° C. in order to increase the adhesive strength. However, in the present invention, since the preheating is performed as described above, the filament 1b of the low melting point fiber and the high melting point are already provided. The fiber filament 1a is in a temporarily fixed state and may be heat-treated at a temperature of at least the melting point of the adhesive layer 3 (for example, about 110 ° C.). As a result, discoloration of the skin material 2 is completely prevented.
[0012]
Next, when the material to be treated is sent to the cooling zone 11b of the heat set chamber 11 in a state where the filament 1b of the low melting point fiber and the adhesive layer 3 are melted as described above, in the cooling zone 11b, 30 It is positively pressurized by the pressure plate 12 whose temperature is adjusted to below. When positive pressurization by the pressure plate 12 is performed immediately after the low melting point fiber filament 1b and the adhesive layer 3 are melted and sent to the cooling zone 11b, Cooling is performed while the compression pressure is dispersed throughout, but the surface of the fibrous web layer 1 and the adhesive layer 3 that are in a molten state in the initial stage of cooling are transmitted with the applied pressure via the skin material 2 and smoothed. The skin material 2 is bonded while being compressed, and at the same time, the fiber web layer is compressed to a predetermined thickness while being cooled in a state where the compression pressure is dispersed throughout the fiber web layer. When the cooling proceeds to 70 to 90 ° C., which is the softening point of the low melting point fiber filament 1b and the adhesive layer 3, the previously melted low melting point fiber filament 1b becomes the high melting point fiber filament 1a in contact therewith. Fuse. When a core-sheath fiber filament is used as the low-melting-point fiber filament 1b, only the sheath part is fused, and the core part is not affected by heat at all, so that the fiber web layer 1 having higher strength is obtained. This is particularly preferable.
[0013]
When the cooling finally proceeds to a temperature range of 10 to 30 ° C. in this cooling zone 11b, the filament 1b of the low melting point fiber and the adhesive layer 3 which are in the softened state are both completely cooled and the adhesive strength is strengthened. At the same time, the mixed fiber web 1 is compressed to a predetermined thickness by being sandwiched between the conveyor belts by the action of the pressure members 14 and 15, and set in this compressed state, so the fiber web 1 is held at the predetermined thickness. It will be. Although the surface of the skin material 2 is in contact with the pressure plate 12 at the time of this pressurization, since the pressure is applied at a low temperature of 30 ° C. or lower, it causes the hair fall phenomenon to occur on the raised material of the skin material 2, No whitening phenomenon occurs, and a product with excellent appearance quality can be produced. Further, since the compression plate 12 is pressurized in a state where the compression pressure is dispersed, the adhesive strength is uniform, Since the skin material 2 is bonded to the fiber web 1 smoothed by pressurization in a molten state via the smoothed adhesive layer 3, the unevenness of the fiber web 1 is obtained even if it is a thin skin material. Therefore, a high-quality product with a smooth surface can be obtained.
[0014]
【The invention's effect】
As is clear from the above description, the present invention produces a product with excellent appearance quality without the surface of the skin material being affected by heat at the time of heat-set processing, without color fading, and without hair fall or whitening. In addition, it is possible to perform mass production efficiently and at low cost by exhibiting excellent productivity.
Therefore, the present invention greatly contributes to the development of the industry as a seat cover manufacturing method that eliminates the conventional problems.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a process of forming a seat cover in an embodiment of the present invention.
FIG. 2 is a cross-sectional view of a seat cover manufactured according to the present invention.
[Explanation of symbols]
1 Fiber web layer
1a Filament of high melting point fiber
1b Low melting point filament 2 Skin material 3 Adhesive layer 4 Back base fabric 5 Preheat set room
10 Needle punch machine
11 Heat set room
11a Heating zone
11b Cooling zone
12 Pressure plate

Claims (6)

高融点繊維と低融点繊維との混合繊維よりなる繊維ウェブ層の表面に熱溶融性の接着層を介して通気性のある表皮材を重ねたうえ前記接着層を熱風の通過により溶融させて表皮材を繊維ウェブ層に接着するとともに繊維ウェブ層をヒートセットするようにしたシートカバーの製造方法において、前記ヒートセットに先立ち繊維ウェブ層を低融点繊維の融点以上の熱風により加熱処理するプリヒートセットを施して低融点繊維が高融点繊維に融着した状態とし、これに表皮材を重ねた後、表皮材が色落ちを起こさない温度以下の熱風を供給してヒートセットを施して繊維ウェブ層の低融点繊維と熱溶融性の接着層とを溶融させ、次いで加圧板により加圧しながら冷却して繊維ウェブ層を所定厚みに圧縮するすることを特徴とするシートカバーの製造方法。A surface of a fiber web layer composed of mixed fibers of high-melting fibers and low-melting fibers is laminated with a breathable skin material through a heat-meltable adhesive layer, and the adhesive layer is melted by passing hot air to obtain a skin. In a sheet cover manufacturing method in which a material is bonded to a fiber web layer and the fiber web layer is heat set, a preheat set for heat-treating the fiber web layer with hot air having a melting point higher than that of the low-melting fiber prior to the heat setting. The low-melting fiber is fused to the high-melting fiber, and after the skin material is overlaid on it, hot air below the temperature at which the skin material does not lose color is supplied and heat set is applied to the fiber web layer. A sheet cover characterized by melting a low-melting fiber and a heat-meltable adhesive layer, and then cooling while pressing with a pressure plate to compress the fiber web layer to a predetermined thickness. Production method. ヒートセットを繊維ウェブ層と表皮材とを積極的に加圧することなく表皮材の表側から繊維ウェブ層の裏側に向けて供給する熱風により行い、次いで加圧板により積極的に加圧しながら冷却して溶融状態にある繊維ウェブ層の表面と接着層を加圧平滑化させつつ表皮材を接着するとともに、繊維ウェブ層を所定厚みに圧縮する請求項１に記載のシートカバーの製造方法。Heat setting is performed by hot air supplied from the front side of the skin material toward the back side of the fiber web layer without positively pressurizing the fiber web layer and the skin material, and then cooled while actively pressing with a pressure plate The method for manufacturing a seat cover according to claim 1, wherein the surface of the fiber web layer in a molten state and the adhesive layer are pressure-smoothed to adhere the skin material, and the fiber web layer is compressed to a predetermined thickness. 表皮材が、起毛を有するファブリック地である請求項１または２に記載のシートカバーの製造方法。The method for manufacturing a seat cover according to claim 1 or 2, wherein the skin material is a fabric having raised hair. 繊維ウェブ層の裏面に高密度不織布構造よりなる裏基布を重ねておく請求項１または２または３に記載のシートカバーの製造方法。The manufacturing method of the seat cover of Claim 1 or 2 or 3 which piles up the back base fabric which consists of a high-density nonwoven fabric structure on the back surface of a fiber web layer. プリヒートセットを行う前に繊維ウェブ層を針刺加工により絡合しておく請求項１または２または３または４に記載のシートカバーの製造方法。The method for manufacturing a seat cover according to claim 1, 2, 3, or 4, wherein the fiber web layer is entangled by needle stab processing before performing preheat setting. 低融点繊維を高融点の芯材に低融点の鞘材を被覆した芯鞘繊維とした請求項１または２または３または４または５に記載のシートカバーの製造方法。The method for producing a seat cover according to claim 1, 2, 3, 4, or 5, wherein the low-melting fiber is a core-sheath fiber in which a low-melting core material is coated with a low-melting sheath material.
JP04221698A 1998-02-24 1998-02-24 Manufacturing method of seat cover Expired - Fee Related JP3637762B2 (en)

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KR100623837B1 (en) * 2000-05-25 2006-09-12 에스케이케미칼주식회사 Method and apparatus for producing thermal-bonded fiber board with high density
KR101414463B1 (en) * 2014-03-27 2014-07-03 주식회사 유엠에스 Preparation method of volume seat cover for motors using heat-press forming and volume seat cover for motors prepared by the same
CN110421678B (en) * 2019-09-06 2024-02-09 辽宁瑷玛特新材料科技有限公司 Cold air setting machine with function of adjusting local air quantity
CN116949665B (en) * 2023-06-20 2024-07-12 浙江中超新材料股份有限公司 Production process and equipment for anti-drilling flock flocculus

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