JP3888497B2 - Nonwoven structure for automotive seat cushion materials - Google Patents
Nonwoven structure for automotive seat cushion materials Download PDFInfo
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- JP3888497B2 JP3888497B2 JP7568598A JP7568598A JP3888497B2 JP 3888497 B2 JP3888497 B2 JP 3888497B2 JP 7568598 A JP7568598 A JP 7568598A JP 7568598 A JP7568598 A JP 7568598A JP 3888497 B2 JP3888497 B2 JP 3888497B2
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Description
【０００１】
【発明の属する技術分野】
本発明は、自動車シートクッション材用不織布構造体に関する。
【０００２】
【従来の技術】
従来、自動車等のシート用クッション材、或いは住宅や病院で使用されるベッドマット材として合成繊維からなる不織布構造体が多く使用されている。例えば特開平１−１８１８３号公報にはポリエステル系短繊維にバインダー繊維を混綿して融着させた不織布構造体が記載されている。しかし、かかる不織布構造体は短繊維からなるため、長期圧縮を行うと除重時に繊維同志の絡みのため回復性が悪く、クッション材には適さないという問題点がある。
【０００３】
また、特開平９−１３７３５０号公報には繊維表面に平滑性油剤を塗布させて繊維同志の摩擦の低減を行い、除重時の回復性を向上させた不織布構造体が記載されている。しかし、かかる不織布構造体はバインダー繊維のポリマーに通常の熱可塑性低融点ポリマーを使用しているため、常温での回復性は良好なものの、そのポリマーの融点近辺の高温雰囲気下においては長期圧縮後の回復性が悪化するという問題点がある。特に自動車等のシート用クッション材の場合、夏場の直射日光下でドアを閉めた状態では室内が７０〜１００℃まで上昇するため、高温雰囲気下で長期荷重をかけた後の回復率が高い素材が求められている。
【０００４】
【発明が解決しようとする課題】
本発明の目的は常温および高温雰囲気下においても、長期圧縮後の回復性が良好で適度なクッション性を保持した自動車シートクッション材用不織布構造体を供給するにある。
【０００５】
【課題を解決するための手段】
本発明者らは繊維の製造方法を研究し、本発明の完成に至った。
即ち、本発明は、マトリックス繊維とバインダー繊維（ただし、バインダー繊維として、結晶融点が１００℃以上の脂肪族ラクトン共重合ポリエステル系バインダー繊維を除く）からなる不織布構造体であって、該マトリックス繊維に高捲縮性繊維及びシリコーン系油剤を塗布した非捲縮の平滑性繊維（以下、単に「平滑性繊維」ともいう）を含み、前記高捲縮性繊維が２種の異なるポリマーからなり、繊維断面において該ポリマーが偏在し、占有面の形状が繊維軸方向に対してほぼ一定であって、該２種の異なるポリマーの熱収縮差によるスパイラル状の捲縮を発現しており、且つ、該バインダー繊維のポリマーの融点が１３０℃以上であり、さらに不織布構造体の密度が０．００５〜０．２ｇ／ｃｍ3 であることを特徴とする自動車シートクッション材用不織布構造体（以下、単に「不織布構造体」ともいう）である。
【０００６】
【発明の実施の形態】
本発明で使用するマトリックス繊維とバインダー繊維のポリマーは特に限定されない。例えばポリエチレンテレフタレートやポリブチレンテレフタレートのようなポリエステル、ポリプロピレンやポリエチレンのようなポリオレフィン、ナイロン６やナイロン６６などのポリアミドおよびこれらの共重合体などを使用することができる。また、これら２種以上の繊維の混合であっても構わない。
【０００７】
マトリックス繊維のうち、前記高捲縮性繊維は２種の異なるポリマーからなり、繊維断面において該ポリマーが偏在し、占有面の形状が繊維軸方向に対してほぼ一定であることが好ましい。
繊維断面において該ポリマーが偏在していると、通常の機械捲縮に加えて加熱処理工程で２種のポリマーの熱収縮差によるスパイラル状の捲縮が発現する。このため繊維自体の反発力がさらに増加し、これを混綿した不織布構造体では除重時の回復性が増大されるため好ましい。
【０００８】
具体的な断面形状については、サイドバイサイド型、シースコア型、多層型、海島型などのコンジュゲートが挙げられる。いずれも加熱時の収縮率が異なるポリマーを選定することで潜在捲縮が発現する。
【０００９】
また中空化、異型断面化を同時に行うことも可能である。中空化の効果として同一の反発力を付与した場合、軽量化が可能となる。このため自動車等のシート用クッション材に用いると燃費の低減による省エネルギー化ができるうえ、コストダウンにも繋がり好ましい。さらに異型断面化の効果として、断面２次モーメント増加の効果により繊維の剛性が向上する。このため同一繊度の場合、繊維自体の反発力がさらに増加し、除重時の回復性がさらに増大されるため好ましい。
【００１０】
本発明に使用するマトリックス繊維のうち、平滑性繊維表面にはシリコーン系油剤が塗布されていることが必要である。具体的にはジメチルポリシロキサン、ジフェニルポリシロキサンなどの非反応性のシリコーン油が挙げられる。これらのシリコーン系油剤が塗布されていない場合、繊維表面の摩擦が増加し、不織布中に使用されている繊維同志の絡みが増大するため、高捲縮性繊維の反発が阻害される。このため長期圧縮後の除重時の回復性が悪化し不適切である。なお、シリコーン系油剤は高捲縮性繊維表面に塗布させても良い。その場合、摩擦がさらに低下するため好ましい。ただしバインダー繊維表面に塗布させると、熱融着による接着が阻害され、成形加工が困難になるため不適切である。
【００１１】
バインダー繊維はそのポリマーの融点が１３０℃以上であることが必要である。１３０℃未満であるとポリマーの結晶性が低いため、７０〜１００℃の高温雰囲気下での長期圧縮時に接着点が変形する。このため、除重時の回復性が悪化し不適切である。特に自動車等のシート用クッション材に用いる場合、夏場の直射日光下でドアを閉めた状態では車内が７０〜１００℃まで上昇する事もあるので、荷重により変形を起こすため不適切である。
【００１２】
バインダー繊維は上記のポリマーよりなる単一成分繊維でもよいが、鞘成分に低融点のポリマー、芯成分にそれより高融点のポリマーを持つシース・コア型コンジュゲート繊維を用いれば、芯成分の支持機能を維持したまま熱融着機能を果たすことができるので更に好適である。かかるバインダー繊維としては通常のポリエチレンテレフタレートポリマーを芯成分に、低融点の共重合ポリエチレンテレフタレートポリマーを鞘成分に持つものが既に市販されているが、これらのみに限定はしない。
【００１３】
また、バインダー繊維の混率は５〜４０％であることが好ましい。この範囲内であると、成形加工時に十分な成形性が保持できるうえ、クッション材として軟らかな触感を持つクッション性が得られるため好ましい。
【００１４】
本発明の不織布構造体は使用時の端部や取り付け部の特殊な箇所を除いた主体部分の平均の厚さが５ｍｍ以上であることが好ましい。平均の厚さが５ｍｍ以上であると、支持体としての十分な剛性が保持でき、固定感や安定感が得られるため好ましい。
【００１５】
さらに不織布構造体の平均の密度が０．００５〜０．２ｇ／ｃｍ3 であることが好ましい。この範囲内であると支持体として十分な剛性が保持できるうえ、嵩高性も得られるため成形加工時の垂れ等が発生せず、好ましい。
【００１６】
これらの不織布構造体は公知の方法によって製造することが可能である。即ち、具体的には原料である綿を開繊、混綿した後にカードを通しウェブを作製し、ニードルパンチをかけて不織布を製造する。さらにこれらの不織布を所定の目付けになるよう積層し、バインダー繊維の低融点ポリマーの融点以上の温度で加熱圧縮による成形を行う。
【００１７】
【発明の効果】
本発明は常温および高温雰囲気下においても長期圧縮後の回復性が良好で適度なクッション性を保持した不織布構造体である。
【００１８】
【実施例】
（常温雰囲気下の回復性の測定方法および評価方法）
１０ｃｍ×１０ｃｍにサンプルを切り出し、初期厚さを測定する。この後サンプルを鉄板に挟んで初期厚さの５０％まで圧縮する。このまま２２℃、６５％ＲＨにて２２ｈｒ放置する。２２ｈｒ後、除重し０．５ｈｒ後に圧縮後厚さを測定し、下記の式より歪み率を算出する。
歪み率（％）＝（初期厚さ−圧縮後厚さ）×１００／初期厚さ
評価は歪み率５％未満を◎、５％以上１０％未満を○、１０％以上１５％未満を△、２０％以上を×とした。
【００１９】
（高温雰囲気下の回復性の測定方法および評価方法）
１０ｃｍ×１０ｃｍにサンプルを切り出し、初期厚さを測定する。この後サンプルを鉄板に挟んで初期厚さの５０％まで圧縮する。このまま乾燥機中７０℃にて２２ｈｒ放置する。２２ｈｒ後、除重し０．５ｈｒ後に圧縮後厚さを測定し、下記の式より歪み率を算出する。
歪み率（％）＝（初期厚さ−圧縮後厚さ）×１００／初期厚さ
評価は歪み率２０％未満を◎、２０％以上２５％未満を○、２５％以上３０％未満を△、３０％以上を×とした。
【００２０】
（クッション性の測定方法および評価方法）
３０ｃｍ×３０ｃｍにサンプルを切り出し、直径２００ｍｍφの円盤で５０ｍｍ／ｍｉｎの一定速度で初期厚さの６５％まで圧縮を行い、その時の荷重を測定する。
評価は６５％圧縮時の硬さが２０ｋｇｆ以上３０ｋｇｆ未満を◎、１７ｋｇｆ以上２０ｋｇｆ未満又は３０ｋｇｆ以上３３ｋｇｆ未満を○、１７ｋｇｆ未満又は３３ｋｇｆ以上を×とした。２０ｋｇｆ以上３０ｋｇｆ未満であると、自動車等のシート用クッション材に用いた場合、適度なクッション性が得られる。また荷重変動によるクッション材の過剰圧縮変形が抑えられ、底付き感も少なくなるため、特に好ましい。
【００２１】
実施例１
表１に示した組成の不織布構造体を通常のカーディング、クロスレイおよび加熱処理により製造した。
製造した不織布構造体の常温雰囲気下の回復性は歪み率４．２％、高温雰囲気下の回復性は歪み率２２．２％であった。またクッション性は６５％圧縮で、圧縮時の硬さが２４．５ｋｇｆであった。これらの評価結果を表２に示す。
【００２２】
実施例２
表１に示した組成の不織布構造体を通常のカーディング、クロスレイおよび加熱処理により製造した。
製造した不織布構造体の常温雰囲気下の回復性は歪み率３．９％、高温雰囲気下の回復性は歪み率１９．４％であった。またクッション性は６５％圧縮で、圧縮時の硬さが２６．５ｋｇｆであった。これらの評価結果を表２に示す。
【００２３】
比較例１
表１に示した組成の不織布構造体を通常のカーディング、クロスレイおよ加熱熱処理により製造した。
製造した不織布構造体の常温雰囲気下の回復性は歪み率４．１％、高温雰囲気下の回復性は歪み率３２．１％であった。またクッション性は６５％圧縮で、圧縮時の硬さが２６．３ｋｇｆであった。これらの評価結果を表２に示す。
【００２４】
比較例２
表１に示した組成の不織布構造体を通常のカーディング、クロスレイおよ加熱熱処理により製造した。
製造した不織布構造体の常温雰囲気下の回復性は歪み率１０．２％、高温雰囲気下の回復性は歪み率２６．５％であった。またクッション性は６５％圧縮で、圧縮時の硬さが２６．０ｋｇｆであった。これらの評価結果を表２に示す。
【００２５】
【表１】
【表２】
BACKGROUND OF THE INVENTION
The present invention relates to a nonwoven fabric structure for automobile seat cushion materials .
[0002]
[Prior art]
Conventionally, nonwoven fabric structures made of synthetic fibers are often used as cushion materials for seats of automobiles, etc., or bed mat materials used in houses and hospitals. For example, Japanese Patent Application Laid-Open No. 1-18183 describes a nonwoven fabric structure in which a polyester fiber is mixed with a binder fiber and fused. However, since such a nonwoven fabric structure is composed of short fibers, there is a problem in that if long-term compression is performed, the recoverability is poor due to the entanglement of the fibers at the time of dewetting and is not suitable for a cushioning material.
[0003]
Japanese Patent Application Laid-Open No. 9-137350 discloses a nonwoven fabric structure in which a smoothing oil is applied to the fiber surface to reduce friction between the fibers and improve the recoverability at the time of dewetting. However, since such a nonwoven fabric structure uses a normal thermoplastic low melting point polymer for the binder fiber polymer, it has good recoverability at room temperature, but after being compressed for a long time in a high temperature atmosphere near the melting point of the polymer. There is a problem that the recoverability of the system deteriorates. Especially in the case of seat cushions for automobiles, etc., when the door is closed under direct sunlight in summer, the interior temperature rises to 70 to 100 ° C, so the material has a high recovery rate after applying a long-term load in a high-temperature atmosphere. Is required.
[0004]
[Problems to be solved by the invention]
An object of the present invention is to provide a nonwoven fabric structure for an automobile seat cushion material that has good recoverability after long-term compression and retains an appropriate cushioning property even under a normal temperature and a high temperature atmosphere.
[0005]
[Means for Solving the Problems]
The inventors of the present invention have studied a method for producing a fiber and have completed the present invention.
That is, the present invention is a non-woven fabric structure comprising a matrix fiber and a binder fiber (excluding an aliphatic lactone copolymer polyester-based binder fiber having a crystal melting point of 100 ° C. or more as a binder fiber), A highly crimped fiber and a non-crimped smooth fiber coated with a silicone-based oil (hereinafter also simply referred to as “smooth fiber”) , the highly crimped fiber comprising two different polymers, and a fiber The polymer is unevenly distributed in the cross section, the shape of the occupied surface is substantially constant with respect to the fiber axis direction, and exhibits a spiral crimp due to a difference in thermal shrinkage between the two different polymers; and the melting point of the binder fiber polymer is at 130 ° C. or higher, automotive sea further the density of the nonwoven fabric structure characterized in that it is a 0.005~0.2g / cm 3 Cushioning material for a non-woven structure (hereinafter, simply referred to as "non-woven structure") it is.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
The polymer of the matrix fiber and binder fiber used in the present invention is not particularly limited. For example, polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyolefins such as polypropylene and polyethylene, polyamides such as nylon 6 and nylon 66, and copolymers thereof can be used. Moreover, you may mix these 2 or more types of fibers.
[0007]
Among the matrix fibers, it is preferable that the highly crimpable fiber is composed of two different polymers, the polymers are unevenly distributed in the fiber cross section, and the shape of the occupied surface is substantially constant with respect to the fiber axis direction.
If the polymer is unevenly distributed in the fiber cross section, in addition to the usual mechanical crimping, spiral crimping due to the difference in thermal shrinkage between the two polymers is manifested in the heat treatment step. For this reason, the repulsive force of the fiber itself is further increased, and a non-woven fabric structure obtained by blending the fibers is preferable because the recoverability at the time of dewetting is increased.
[0008]
Specific examples of the cross-sectional shape include conjugates such as a side-by-side type, a seascore type, a multilayer type, and a sea-island type. In any case, latent crimp is developed by selecting polymers having different shrinkage ratios upon heating.
[0009]
It is also possible to make the hollow and the modified cross section simultaneously. When the same repulsive force is applied as a hollowing effect, the weight can be reduced. For this reason, when it is used for a cushion material for a seat such as an automobile, it is possible to save energy by reducing fuel consumption, and it leads to cost reduction. Furthermore, the rigidity of the fiber is improved by the effect of increasing the second moment of section as an effect of making the modified section. For this reason, in the case of the same fineness, since the repulsive force of fiber itself further increases and the recoverability at the time of dewetting is further increased, it is preferable.
[0010]
Of the matrix fibers used in the present invention, it is necessary that the surface of the smooth fiber is coated with a silicone-based oil. Specific examples include non-reactive silicone oils such as dimethylpolysiloxane and diphenylpolysiloxane. When these silicone-based oils are not applied, the friction on the fiber surface increases and the entanglement of fibers used in the nonwoven fabric increases, so that the repulsion of highly crimped fibers is inhibited. For this reason, the recoverability at the time of dehumidification after long-term compression deteriorates and is inappropriate. The silicone oil may be applied to the highly crimpable fiber surface. In that case, the friction is further reduced, which is preferable. However, if it is applied to the surface of the binder fiber, it is unsuitable because adhesion due to heat fusion is hindered and molding becomes difficult.
[0011]
The binder fiber is required to have a polymer melting point of 130 ° C. or higher. When the temperature is lower than 130 ° C, the crystallinity of the polymer is low, so that the adhesion point is deformed during long-term compression in a high temperature atmosphere of 70 to 100 ° C. For this reason, the recoverability at the time of weight reduction deteriorates and is inappropriate. In particular, when used for a cushion material for a seat of an automobile or the like, the interior of the vehicle may rise to 70 to 100 ° C. when the door is closed under direct sunlight in summer.
[0012]
The binder fiber may be a single component fiber made of the above-mentioned polymer, but if a sheath / core conjugate fiber having a low melting point polymer for the sheath component and a higher melting point polymer for the core component is used, the core component is supported. It is further preferable because the heat fusion function can be achieved while maintaining the function. As such binder fibers, those having an ordinary polyethylene terephthalate polymer as a core component and a low-melting copolymer polyethylene terephthalate polymer as a sheath component are already commercially available, but are not limited thereto.
[0013]
Moreover, it is preferable that the mixture rate of a binder fiber is 5 to 40%. Within this range, it is preferable because sufficient formability can be maintained during the molding process, and cushioning properties with a soft tactile feel can be obtained as a cushioning material.
[0014]
In the nonwoven fabric structure of the present invention, it is preferable that the average thickness of the main portion excluding special portions such as end portions and attachment portions in use is 5 mm or more. An average thickness of 5 mm or more is preferable because sufficient rigidity as a support can be maintained and a sense of fixation and stability can be obtained.
[0015]
Furthermore, it is preferable that the average density of a nonwoven fabric structure is 0.005-0.2 g / cm < 3 >. Within this range, it is preferable that sufficient rigidity can be maintained as a support and bulkiness is obtained, so that no dripping or the like occurs during molding.
[0016]
These nonwoven fabric structures can be manufactured by a known method. Specifically, the raw material cotton is opened and mixed, and then a card is made through a card, and a nonwoven fabric is produced by needle punching. Further, these non-woven fabrics are laminated so as to have a predetermined basis weight, and are molded by heat compression at a temperature equal to or higher than the melting point of the low melting point polymer of the binder fiber.
[0017]
【The invention's effect】
The present invention is a nonwoven fabric structure having good cushioning properties and good recoverability after long-term compression even at room temperature and high-temperature atmosphere.
[0018]
【Example】
(Measurement method and evaluation method of recoverability under normal temperature atmosphere)
A sample is cut out to 10 cm × 10 cm, and the initial thickness is measured. Thereafter, the sample is sandwiched between iron plates and compressed to 50% of the initial thickness. This is left for 22 hours at 22 ° C. and 65% RH. After 22 hours, the weight is removed, the thickness after compression is measured after 0.5 hours, and the strain rate is calculated from the following equation.
Strain rate (%) = (initial thickness−thickness after compression) × 100 / initial thickness evaluation is as follows: strain rate is less than 5%, ◎ 5% to less than 10%, ◯ 10% to less than 15%, 20% or more was set as x.
[0019]
(Measurement method and evaluation method of recoverability in high-temperature atmosphere)
A sample is cut out to 10 cm × 10 cm, and the initial thickness is measured. Thereafter, the sample is sandwiched between iron plates and compressed to 50% of the initial thickness. This is left in the dryer at 70 ° C. for 22 hours. After 22 hours, the weight is removed, the thickness after compression is measured after 0.5 hours, and the strain rate is calculated from the following equation.
Strain rate (%) = (initial thickness−thickness after compression) × 100 / initial thickness evaluation is ◎ if strain rate is less than 20%, ○ if 20% or more and less than 25%, ％ if 25% or more and less than 30%, 30% or more was set as x.
[0020]
(Measurement method and evaluation method of cushioning properties)
A sample is cut out to 30 cm × 30 cm, and compressed to 65% of the initial thickness at a constant speed of 50 mm / min with a disk having a diameter of 200 mmφ, and the load at that time is measured.
In the evaluation, the hardness at 65% compression was 20 kgf or more and less than 30 kgf, ｆ, 17 kgf or more but less than 20 kgf, or 30 kgf or more and less than 33 kgf, ○, and less than 17 kgf or 33 kgf or more. When it is 20 kgf or more and less than 30 kgf, an appropriate cushioning property can be obtained when used for a cushion material for a seat such as an automobile. Further, it is particularly preferable because excessive compression deformation of the cushion material due to load fluctuation is suppressed and the feeling of bottoming is reduced.
[0021]
Example 1
Nonwoven structures having the compositions shown in Table 1 were produced by ordinary carding, cross-laying, and heat treatment.
The recoverability of the manufactured nonwoven fabric structure under a normal temperature atmosphere was 4.2% strain rate, and the recoverability under a high temperature atmosphere was 22.2% strain rate. The cushioning property was 65% compression, and the hardness at the time of compression was 24.5 kgf. These evaluation results are shown in Table 2.
[0022]
Example 2
Nonwoven structures having the compositions shown in Table 1 were produced by ordinary carding, cross-laying, and heat treatment.
The recoverability under normal temperature atmosphere of the manufactured nonwoven fabric structure was 3.9% strain rate, and the recoverability under high temperature atmosphere was 19.4% strain rate. The cushioning property was 65% compression, and the hardness at the time of compression was 26.5 kgf. These evaluation results are shown in Table 2.
[0023]
Comparative Example 1
Nonwoven structures having the compositions shown in Table 1 were produced by ordinary carding, cross-laying, and heat treatment.
The recoverability of the manufactured nonwoven fabric structure under a normal temperature atmosphere was 4.1% strain rate, and the recoverability under a high temperature atmosphere was 32.1% strain rate. The cushioning property was 65% compression, and the compression hardness was 26.3 kgf. These evaluation results are shown in Table 2.
[0024]
Comparative Example 2
Nonwoven structures having the compositions shown in Table 1 were produced by ordinary carding, cross-laying, and heat treatment.
The recoverability of the manufactured nonwoven fabric structure under a normal temperature atmosphere was 10.2% strain rate, and the recoverability under a high temperature atmosphere was 26.5% strain rate. The cushioning property was 65% compression, and the hardness at the time of compression was 26.0 kgf. These evaluation results are shown in Table 2.
[0025]
[Table 1]
[Table 2]
Claims (3)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7568598A JP3888497B2 (en) | 1998-03-24 | 1998-03-24 | Nonwoven structure for automotive seat cushion materials |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7568598A JP3888497B2 (en) | 1998-03-24 | 1998-03-24 | Nonwoven structure for automotive seat cushion materials |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH11279918A JPH11279918A (en) | 1999-10-12 |
| JP3888497B2 true JP3888497B2 (en) | 2007-03-07 |
Family
ID=13583306
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP7568598A Expired - Fee Related JP3888497B2 (en) | 1998-03-24 | 1998-03-24 | Nonwoven structure for automotive seat cushion materials |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3888497B2 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006223707A (en) * | 2005-02-21 | 2006-08-31 | Kanebo Ltd | Nonwoven fabric structure, seat cushion material, and vehicle seat consisting of the same |
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1998
- 1998-03-24 JP JP7568598A patent/JP3888497B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH11279918A (en) | 1999-10-12 |
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