JP3656287B2 - Cushion base material for seat cover and method for manufacturing the same - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a cushion base material for a seat cover for an automobile or the like that has a surface structure of a seat (seat) of an automobile, for example, and a method for manufacturing the cushion base material.
[0002]
[Prior art]
2. Description of the Related Art An automobile seat cover that is a surface structure of an automobile seat is widely used in which a skin material is superimposed on one side of a cushion material that serves as a cushion base material. The cushion material is mainly composed of an ester-based urethane foam having an ester polyol as a main raw material and an ether-based urethane foam having an ether polyol, and is generally referred to as a slab urethane foam. In Japan, ether-based urethane foam is the mainstream in consideration of hydrolysis resistance of the urethane structure. On the other hand, as the skin material, a structure such as warp knitted knit (tricot or w rassell), warp knitted knit (jersey), and woven fabric (plain weave, moquette) mainly using polyester yarn is used according to the skin design.
[0003]
The slab urethane foam and the skin material are cut into a predetermined shape, and then overlapped and sewn to form an automobile seat cover. However, there is a troublesome problem in sewing the slab urethane home and the skin material. In other words, the slab foam, which is a sewn body, has poor slipping on the sewing machine work surface, which causes deviations from the skin material and irregular needle pitch, making it difficult to perform stable sewing work. It is difficult to maintain quality as a seat cover.
[0004]
Some attempts to solve this troublesome problem have been made in the past. One of them is a method of bonding a slippery fabric as a lining to the back surface of the slab urethane foam. Nylon yarn, polyester yarn, or cellulose yarn is used as a fabric for improving slipperiness, and a plain woven fabric using cotton yarn in addition to a warp knitted fabric (tricot half) or weft knitted fabric (tenji knitting). A twill fabric and a nonwoven fabric made of nylon or polyester are used.
[0005]
As shown in FIG. 9, the slab urethane foam 101 is bonded to the fabric in addition to a method using a hot-melt adhesive, a solvent-based adhesive, a water-soluble adhesive, or the like. A frame laminating method is also employed in which a flame 102 is applied to one side of the film and the fabric 103 is bonded using melted urethane as an adhesive. Furthermore, there are cases where the sewing work is enhanced by integrating the skin material, the slab urethane foam, and the fabric into a three-layer structure.
[0006]
The other one is a method in which a polyethylene film 104 is thermally fused and coated on one side of a slab urethane foam 101 using a hot roll 105 as shown in FIG. In this case, since the polyethylene film 104 itself has a problem in heat fusion with urethane, it has been devised to have a two-layer structure with an acrylic film having a relatively low melting point and good compatibility with urethane. Yes. According to this method, the film 104 can be attached to the slab urethane foam 101 with almost no form, and the elongation characteristics of the slab urethane foam 101 are hardly impaired.
[0007]
[Problems to be solved by the invention]
In the former method for imparting slipperiness to the conventional slab urethane foam 101 as described above, the fabric 103 is bonded only for imparting slipperiness to the slab urethane foam 101, which is costly and tends to be excessive quality. is there. In addition, when a relatively low-cost nonwoven fabric is used as the fabric 103, the nonwoven fabric generally has almost no stretchability. Therefore, when a three-layer structure is used, the quality of the bent portion as shown in FIG. A fold (which is said to be a lami fold) 106 is likely to occur. Lami fold 106 can be prevented as a fabric having stretchability on the yarn itself by applying special processing to impart crimpability to the yarn, but the fabric is extremely expensive and is not cost effective.
[0008]
In the latter case, the problem of the lamellar fold 106 does not occur, but as the molten state of the polyethylene film 104 increases, the processing speed decreases and the productivity deteriorates. Actually, it is considerably low, about 1/2 to 1/3 of the processing speed of the frame laminating method. In the frame laminating method, the skin surface and the back ground are generally processed at the same time to increase productivity. However, there is a difference in processing speed in this method, and it is not possible to perform simultaneous processes.
[0009]
The present invention has been made to solve the above-described conventional problems, and the problem is that a stable sewing operation with the skin material can be performed, and a low-cost and high-quality seat cover for automobiles is obtained. It is providing the cushion base material of the seat cover which can be provided, and providing the manufacturing method which manufactures the cushion base material with sufficient productivity. That is, according to the present invention, it is possible to provide a cushion base material suitable for an automobile seat cover, a normal chair seat cover, or a sofa seat cover, and a method for manufacturing the same.
[0010]
[Means for Solving the Problems]
To achieve the above object, the cushion base seat cover for an automobile which is sewn by superposing fibrous surface material on the surface, the whole minute protrusions having a sliding property on the back surface of the sheet-shaped cushion material It is possible to adopt means for distributing and configuring in the protruding state .
[0011]
To achieve the above object, the recesses of the transfer surface of the transfer roller with the outer periphery were uniformly distributed minute indentations transfer surface, a resin having slip property against hard plate surface at room temperature after the resin was melted Rotate while filling the molten resin, and cushion the molten resin that has been filled in the small dents of the transfer surface by pressing one side of the cushion material of the belt-shaped sheet to the transfer surface of this rotating transfer roller while feeding it out It is possible to adopt a means for transferring projections on one side and forming projections with fine resin particles on the entire side .
[0012]
To achieve the above object, in the groove of the transfer surface of the transfer roller with the outer peripheral transfer surface fine grooves are uniformly distributed over the entire circumference, with sliding against stiff plate surface at room temperature The resin is rotated while being filled with a molten resin in a molten state, and one side of the cushion material of the belt-like sheet is brought into pressure contact with the transfer surface of the rotating transfer roller while being fed into a minute groove on the transfer surface. It is possible to employ means for transferring the filled molten resin to one side of the cushion material to form minute resin protrusions on the entire one side .
[0013]
In order to achieve the above object, the invention of claim 1 has a plurality of minute leaching holes having one end inside and the other end opening on the outer surface, and one opening end of each leaching hole is uniform. In the inside of the transfer roller with the transfer surface distributed on the outer periphery, a molten resin that is melted with a resin that is hard at room temperature and has a slipperiness with respect to the plate surface is press-fitted and leached from the above leaching holes to the transfer surface Rotating the transfer roller, one side of the cushion material of the belt-like sheet is brought into pressure contact with the transfer surface of the rotating transfer roller, and the molten resin leached to the opening end of each leaching hole of the transfer surface is cushioned A means is adopted that is transferred to one side of the film and forms projections of minute resin particles on the entire side.
[0014]
[Action]
A cushion base material for an automobile seat cover that is sewn with a fibrous skin material superimposed on the surface, and is configured by distributing minute protrusions with sliding properties on the back surface of the sheet-like cushion material in a protruding state as a whole. By adopting the means to do so, the slip on the sewing machine work surface of the cushion base material when sewing with the fibrous skin material superimposed on the surface is improved by the minute protrusions with the slipperiness distributed on the back surface, The stretchability of the cushion base material is not impaired. In addition, the cushion base material slipping on the sewing machine work surface when sewing with the fibrous skin material superimposed on the front surface is improved by the small protrusions with slipperiness distributed on the back surface, and the cushion base material expands and contracts. Therefore, a stable sewing operation with the skin material can be performed, and a high-quality seat cover can be obtained at low cost.
[0015]
The transfer roller having a transfer surface with a uniform distribution of the minute dents on its outer periphery is filled with a molten resin in which the dent on the transfer surface is melted with a resin that is hard and slippery at normal temperatures. Then, one side of the cushion material of the belt-shaped sheet is brought into pressure contact with the transfer surface of the rotating transfer roller, and the molten resin filled in the minute recesses on the transfer surface is transferred to one side of the cushion material to make a minute amount. If a means for forming projections with simple resin particles on the entire surface is adopted, it is rotated while filling a small dent on the transfer surface with molten resin having slipperiness, and the belt-like sheet is transferred to the transfer surface of the rotating transfer roller. By pressing and pressing one side of the cushion material, the molten resin in the dent can be continuously transferred to one side of the cushion material without damaging the elasticity of the cushion material. It can be continuously form a projection by the fat particles in the entire one surface of the cushion material. Furthermore, a stable sewing operation with the skin material can be performed, and a cushion base material capable of obtaining a high-quality seat cover at low cost can be manufactured with high productivity.
[0016]
Melting resin in a molten state, which is hard at normal temperature and has slipperiness to the plate surface, in each groove on the transfer surface of the transfer roller having a transfer surface on the outer periphery where the fine grooves are uniformly distributed over the entire circumference. Rotate while filling the resin, and press the molten resin that has been filled in the minute grooves on the transfer surface by pressing one side of the cushion material of the belt-like sheet to the transfer surface of the rotating transfer roller while feeding it out. If you use a means to transfer the cushioning material to one side and form minute resin protrusions on the entire surface , the transfer is rotating while filling the minute groove on the transfer surface while filling it with slippery molten resin. By continuously pressing one side of the cushion material of the belt-like sheet to the transfer surface of the roller while feeding it out, the molten resin in the groove is continuously transferred to one side of the cushion material without impairing the elasticity of the cushion material. Can, it is possible to continuously form minute resin projections on one entire surface of the cushion material. Furthermore, a stable sewing operation with the skin material can be performed, and a cushion base material capable of obtaining a high-quality seat cover at low cost can be manufactured with high productivity.
[0017]
In claim 1, a molten resin having slipperiness is press-fitted inside the transfer roller, and the transfer roller is rotated while the molten resin is leached from the leaching holes to the transfer surface of the transfer roller. By pressing and pressing one side of the cushion material of the belt-like sheet to the transfer surface, the molten resin leached at the opening end of each leaching hole on the transfer surface continuously impairs the stretchability of the cushion material on one side of the cushion material. The projection can be continuously formed on the entire surface of the cushion material.
[0018]
【Example】
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
(Embodiment 1) FIG. 1 is an enlarged sectional view showing the structure of an automobile seat cover as one embodiment of the present invention, and FIG. 2 is a plan view showing the structure of the back surface of the cushion base material. The automobile seat cover shown in FIG. 1 is configured by superposing a skin material 2 on one side of a cushion base material 1. The cushion base material 1 is configured by molding resin particles 3 on a sheet-like cushion material 4 made of an ester urethane foam as an ester polyol or an ether urethane foam as an ether polyol by dot processing. That is, on the back surface of the cushion base material 1, fine resin particles 3 having a sliding property of 2 mm to 3 mm in diameter and arranged in the vertical and horizontal directions with a pitch of 5 mm to 7 mm are combined and distributed in a protruding state as a whole.
[0019]
The resin particles 3 are mainly formed of a polyester resin or a nylon resin having a small coefficient of friction with the surface of the sewing machine table (usually a decorative board subjected to acrylic processing). In addition, the skin material 2 is fibrous, and the organization of warp knitting knit (tricot and w rassell), warp knitting knit (jersey), fabric (plain weaving, moquette), etc., mainly polyester yarn, depends on the skin design It is used.
[0020]
The cushion base material 1 and the skin material 2 provided with the resin particles 3 are cut into a predetermined shape, and then overlapped and sewed with the back surface of the cushion base material 1 with the resin particles 3 applied to the surface of the sewing machine table. The vehicle seat cover as shown in FIG. In FIG. 1 and FIG. 2, S is a sewing part. In this sewing, slipping on the sewing machine work surface of the cushion base material 1 is extremely good, and there is no inconvenience that deviation from the skin material 2 or irregular needle pitch occurs, and stable sewing work can be performed. I was able to do it. The resin particles 3 are minute and do not incur material costs, and the stretchability of the cushion base material 1 itself is not impaired. Therefore, the resin particles 3 can be formed at low cost, and so-called laminating or the like does not occur. The coefficient of friction between the acrylic plates of the cushion base material 1 is a very small value of 0.15 to 0.30. Incidentally, the coefficient of friction of the nylon-based fabric is 0.10 to 0.18, the coefficient of friction of the polyester film is 0.20 to 0.22, and slab urethane foam (the cushion material itself). The friction coefficient of the single thing was 0.85-1.00. In addition, the resin particle 3 can obtain a substantially equivalent sliding function as a minute rib-shaped resin protrusion 3a as shown in FIG. In addition, S of FIG. 3 shows a sewing part.
[0021]
(Example 2) This Example 2 relates to a manufacturing method for manufacturing the cushion base material 1 having the resin particles 3 shown in Example 1 on one side. As shown in FIG. The resin base material 3 is continuously molded to produce the cushion base material 1. That is, as shown in FIGS. 4 and 5, one side of the cushion material 4 formed on the belt-like sheet is brought into pressure contact with the transfer roller 7 having the transfer surface 6 on which the minute dents 5 are uniformly distributed on the outer periphery. Is. The transfer roller 7 is horizontally mounted on the molten resin tank 8 so that the lower side of the transfer surface 6 is always immersed in the molten resin 9, and is rotated in a fixed direction at a fixed speed.
[0022]
As shown in FIG. 5, the transfer surface 6 is mirror-finished. On the surface, recesses 5 having a pitch of 5 mm to 7 mm, a diameter of 2 mm to 3 mm, and a depth of 1 to 2 mm are formed in the vertical and horizontal directions. The entire surface is surface treated with a fluorine resin. In the molten resin tank 8, a thermoplastic resin having a melting point of about 160 ° C. that is hard at room temperature and has slipperiness with respect to the plate surface is maintained at a temperature about 20 ° C. higher than the melting point and is stored in a molten state. Polyester resin and nylon resin are used as the thermoplastic resin. In consideration of the control of viscosity at the time of melting and adhesiveness with urethane foam, wax components are mixed in or adjusted to an adhesively active molecular structure. Yes.
[0023]
The leading edge of the doctor knife 10 is applied to the front side in the rotational direction from the resin immersion portion of the transfer roller 7. This doctor knife 10 acts to scrape off the molten resin 9 adhering to portions other than the recess 5 of the transfer surface 6. The transfer surface 6 of the transfer roller 7 that has passed the doctor knife 10 is filled with the molten resin 9 only in the recess 5. If one side of the cushion material 4 of the belt-like sheet is pressed against the transfer surface 6 at the upper part of the transfer roller 7 while being fed while being wound, the melt filled in the recess 5 on one side of the cushion material 4 As shown in Example 1, the resin 9 is continuously transferred, and in the cooling step K behind the guide roller 11A, cooling is performed with cold air or the like, so that protrusions with minute resin particles 3 are formed on one surface of the cushion material 4. The cushion base material 1 is obtained.
[0024]
According to this manufacturing method, a processing speed exceeding 20 mm per minute is possible, and the processing speed can be synchronized. Therefore, the integration of the skin material 2 to which the frame laminating method is applied can be performed in the same process. Since the molten resin 9 is bonded in a form close to point bonding, the stretchability of the cushion material 4 is not impaired, and an inexpensive and easy-to-handle cushion base material 1 that does not cause breakage of the laminate can be produced with high productivity. Moreover, it is possible to easily impart flame retardancy to the molten resin 9, and the cushion base material 1 having flame retardancy can also be manufactured without adding special equipment.
[0025]
If an appropriate cooling mechanism for cooling the transfer surface 6 of the transfer roller 7 is provided, the portion of the molten resin 9 filling the recess 5 that is in contact with the recess 5 is first cured, and the cushion material 4 Since the resin on the contact surface is delayed in curing, the processing speed can be further increased without impairing the adhesiveness.
[0026]
(Embodiment 3) In Embodiment 3, as shown in FIG. 6, a minute resin protrusion is formed on the cushion material 4 by a transfer roller 7 having a transfer surface 6 on the outer periphery in which minute grooves 12 are uniformly distributed over the entire circumference. The present invention relates to a method of manufacturing the cushion base material 1 having the minute resin protrusions 3a shown in FIG. Actually, it can be carried out as it is by the equipment and method of Example 2 just by making the recess 5 of the transfer roller 7 in Example 2 into the groove 12, and the same effect is obtained.
[0027]
(Embodiment 4) This embodiment 4 relates to a manufacturing method for manufacturing the cushion base material 1 having the resin particles 3 shown in the embodiment 1 on one side in the same manner as the embodiment 2, and the cushion material 4 is also transferred by transfer. The resin particles 3 are formed continuously. That is, as shown in FIGS. 7 and 8 (a) and 8 (b), the transfer roller 7 shown in the second embodiment has a plurality of minute leaching holes 13 with one end opened inside and the other end opened outside. And the transfer surface 7 in which one opening end of each of the leaching holes 13 is uniformly distributed is replaced with a transfer roller 7 configured on the outer periphery, whereby the resin particles 3 are transferred.
[0028]
As shown in FIG. 8A, the transfer roller 7 has a structure in which the molten resin 9 can be supplied to the inside of the transfer roller 7 rotatably supported by a bearing 20 by a liquid feeding pipe 21. The inside of the transfer roller 7 is configured as a storage portion 14 for the molten resin 9, and the thermoplastic resin shown in the second embodiment is pressed in a molten state. As shown in FIG. 8 (b), each leaching hole 13 communicates with the reservoir 14 to form a resin reservoir 15 having a pitch of 5 to 7 mm, a diameter of 2 mm to 3 mm, and a depth of 1 to 2 mm on the transfer surface 6 in the vertical and horizontal directions. It is open. That is, the molten resin 9 accumulated in the resin reservoir 15 is continuously transferred to the cushion material 4 by the centrifugal force generated by the rotation of the transfer roller 7 and the internal pressure of the reservoir 14. Therefore, the facilities of the molten resin tank 8 and the doctor knife 10 shown in Example 2 are unnecessary. Since the other equipment configuration and the characteristics of the manufacturing method are the same as those of the second embodiment, the same parts are denoted by the same reference numerals in the drawings, and description thereof will be omitted.
[0029]
In each of the above-described embodiments, the cushion base material for an automobile seat cover and the manufacturing method thereof have been mainly described. However, the present invention is not limited to this, and a fibrous skin material is stacked on the surface and sewn. If it is a seat cover, it can also be adopted as a cushion base material for a normal seat cover for a chair or a seat cover for a sofa and a manufacturing method thereof.
[0030]
【The invention's effect】
According to the invention of claim 1, a cushion base material capable of performing a stable sewing operation with the skin material and obtaining a high-quality seat cover at a low cost can be manufactured with high productivity.
[Brief description of the drawings]
FIG. 1 is an enlarged cross-sectional view showing the structure of an automobile seat cover according to an embodiment of the present invention.
2 is a view showing a back surface structure of a cushion base material of the automobile seat cover of FIG. 1. FIG.
FIG. 3 is a view showing a back surface structure of a cushion base material of an automobile seat cover as another embodiment of the present invention.
FIG. 4 is an equipment configuration diagram showing an embodiment of a method for producing a cushion base material according to the present invention.
5 is an enlarged partial sectional view of a transfer surface of the transfer roller in FIG. 4;
FIG. 6 is a perspective view of a transfer roller used in the embodiment of the cushion base material manufacturing method of the present invention.
FIG. 7 is an equipment configuration diagram showing an embodiment of a method of manufacturing a cushion base material according to the present invention.
8A is a structural diagram of the transfer roller of FIG. 7, and FIG. 8B is an enlarged partial cross-sectional view of the transfer surface of the transfer roller of FIG.
FIG. 9 is an explanatory view showing an example of a conventional method for producing a cushion material.
FIG. 10 is an explanatory view showing an example of a conventional method for producing a cushion base material.
FIG. 11 is an explanatory view showing a lami-folding of a conventional cushion base material.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Cushion base material 2 Skin material 3 Resin particle | grains 4 Cushion material 5 Indentation 6 Transfer surface 7 Transfer roller 9 Molten resin 12 Groove | groove 13 Leaching hole 14 Storage part 15 Resin pool

Claims (1)

The inside of a transfer roller that has a plurality of minute leaching holes with one end on the inside and the other end opening on the outer surface on the entire circumference, and a transfer surface in which one opening end of each leaching hole is uniformly distributed on the outer periphery. Furthermore, the transfer roller is rotated while being pressed into the transfer surface from each of the above leaching holes by press-fitting a molten resin in a molten state that is hard and slippery with respect to the plate surface at room temperature. One side of the cushion material of the belt-like sheet is pressed against the transfer surface while being fed out, and the molten resin leached to the opening end of each leaching hole of the transfer surface is transferred to one side of the cushion material, and projections by minute resin particles are provided on one side A method for producing a cushion base material for a seat cover, characterized by being formed entirely.

Images