JP4220311B2 - Manufacturing method of seat pad - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a seat pad used for a vehicle or furniture seat.
[0002]
[Prior art]
Conventionally, for example, in a cushion pad for an automobile seat, in order to suppress breakage due to friction with the seat frame and generation of abnormal noise, a backing material such as felt or a coarse blanket is integrally laminated on the back surface of the pad. There are many. Such a backing material is generally set on the upper mold via a mounting pin provided on the upper mold, and is laminated and integrated on the back surface of the pad main body, which is a foam, by injecting foaming material into the lower mold and foaming. ing.
[0003]
As such a backing material, the following Patent Document 1 discloses a technique of using a stretchable nonwoven fabric such as a spunbond nonwoven fabric of a thermoplastic polyurethane elastomer in order to eliminate the uncomfortable feeling and uncomfortable feeling at the time of sitting and improve the sitting comfort. Has been proposed.
[0004]
[Patent Document 1]
Japanese Patent No. 3056605 [0005]
[Problems to be solved by the invention]
The stretchable nonwoven fabric is very effective from the viewpoint of improving ride comfort, but on the other hand, at the time of production, the nonwoven fabric alone is too soft and has no waist, and therefore has the following problems.
[0006]
That is, (1) When an operator who sets a stretchable nonwoven fabric in an upper mold takes a stretchable nonwoven fabric from a storage location, he or she takes a plurality of sheets simultaneously and sets them as they are. (2) Since it is difficult to insert the stretchable nonwoven fabric into the mounting pin, it has been set in the foaming mold at the last minute in combination with the recent increase in production line speed. (3) For this reason, the mounting pin may come off without being fully set. (4) In addition, after the set, the foaming mold is removed with the momentum of closing, which becomes a target for repair and failure.
[0007]
The present invention has been made in view of such points, greatly improving the manufacturing workability of the pad for the sheet integrated with the stretchable nonwoven fabric on the back surface, reducing the defect rate, the repair rate, As a result, it aims at providing the manufacturing method of the pad for sheets which can aim at cost reduction.
[0008]
[Means for Solving the Problems]
The sheet pad manufacturing method of the present invention includes a stretchable nonwoven fabric set on the inner surface of the upper mold of a foam mold comprising a lower mold and an upper mold, and a foam raw material is injected into the cavity of the foam mold. A sheet pad in which the stretchable nonwoven fabric is integrated on the back surface by foaming, and penetrates a predetermined portion of the stretchable nonwoven fabric to the inner surface of the upper mold of the foaming mold. A plurality of mounting pins that support the stretchable nonwoven fabric are provided, and a reinforcing sheet made of a sheet material that is less stretchable than the stretchable nonwoven fabric is attached to a portion of the stretchable nonwoven fabric that is penetrated by the mounting pin , and this is reinforced. and said reinforcing sheet is attached portion of the stretchable nonwoven fabric, in a state with its surface on the side where the reinforcing sheet is attached to the cavity side, by pressing the mounting pins, the Chakupin in that pass through the reinforcing sheet with the stretchable nonwoven fabric, characterized by setting said stretchable nonwoven fabric to the foam molding mold.
[0010]
Such a production method of the present invention, the through predetermined position of the mounting pin in the stretchable nonwoven fabric in advance to reinforce the said through scheduled position by the reinforcing sheet Ru provided as a reinforcing layer by inserting the mounting pin into the reinforced portion Set the stretchable nonwoven fabric in the foaming mold. As described above, since the partially reinforced stretchable nonwoven fabric is set in the foaming mold, it is easy to handle, the burden on the operator is reduced, the mounting mistake is reduced, and the stretchable nonwoven fabric is detached. The defect rate and repair rate can be greatly reduced.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
[0012]
As shown in FIG. 3, the seat pad according to the present embodiment is a seat cushion pad 10 for an automobile seat, and includes a pad main body 12 made of a synthetic resin foam molded body having elasticity such as a flexible polyurethane foam, and the like. The stretchable nonwoven fabric 14 is integrally formed over substantially the entire back surface (lower surface) of the pad main body 12.
[0013]
The stretchable nonwoven fabric 14 is preferably a nonwoven fabric made of elastic fibers and having a break elongation of 150% or more. More specifically, the elastic fiber made of polyurethane or rubber elastomer is used as a raw material, for example, a non-woven fabric manufactured by a spunbond method or a melt blow method, and has a high elongation and a high recovery rate comparable to those of a flexible polyurethane foam. It is desirable to select and use a conductive nonwoven fabric, the elongation at break is preferably 150 to 600%, and the basis weight is preferably about 50 to 300 g / m ² . As stretchable nonwoven fabrics having such properties, thermoplastic polyurethane elastomer spunbond nonwoven fabrics (for example, “Espancione” (trade name), manufactured by Kanebo Co., Ltd.), melt blown nonwoven fabrics comprising styrene / hydrogenated polyisoprene block copolymers (For example, “Septon MB” (trade name), manufactured by Kuraray Co., Ltd.).
[0014]
As shown in FIG. 1, the foaming mold 20 used for manufacturing the seat cushion pad 10 is rotatable via a lower mold 22 that opens upward and a hinge portion 24 disposed on one side of the lower mold 22. And an upper mold 26 that opens and closes the upper surface opening of the lower mold 22. Specifically, the lower die 22 is a die that molds the surface (upper surface) side of the pad, and has a concave portion corresponding thereto. The upper mold 26 is a mold for molding the back surface (lower surface) side of the pad, and corresponds to the pad shape between the lower mold 22 and the inner surface of the mating surface (PL section) by closing the concave portion. A cavity that is a foaming space is formed.
[0015]
The upper mold 26 is provided with a plurality of mounting pins 28 at predetermined positions in order to set the stretchable nonwoven fabric 14 on the inner surface thereof. As shown in FIG. 2, the mounting pin 28 is provided so as to protrude into the cavity from the inner surface of the upper mold 26, the tip is pointed in a taper shape, and pierces and penetrates a predetermined portion of the stretchable nonwoven fabric 14. Thus, the elastic nonwoven fabric 14 is detachably locked to the surface of the upper mold 26 in the cavity. The arrangement position and the number of the mounting pins 28 are not particularly limited as long as the elastic nonwoven fabric 14 can be supported entirely on the inner surface of the upper mold 26. As an example, in this embodiment, the front end portion of the seat cushion pad 10 and They are provided at two positions on the left and right sides at the rear end (see FIGS. 1, 3, and 4).
[0016]
A reinforcing sheet 16 is attached to the stretchable nonwoven fabric 14 at a portion through which the mounting pin 28 penetrates. The reinforcing sheet 16 is a sheet material having a size that surrounds the mounting pin 28 and is a non-stretchable material such as a coarse blanket or a felt as long as it is a sheet material that is less stretchable than the stretchable nonwoven fabric 14. Alternatively, other than a low stretch cloth, paper, a resin sheet, or the like can be used. Preferably, a rough blanket with a low basis weight (weight per unit area 50 to 200 g / m ² ) is used. Moreover, as a method of attaching the reinforcing sheet 16 to the stretchable nonwoven fabric 14, it can be fixed by a stapler, a tag, or the like, in addition to a method using sewing or an adhesive.
[0017]
When the seat cushion pad 10 is manufactured using the foaming mold 20, the stretchable nonwoven fabric 14 reinforced by the above-described reinforcing sheet 16 is set on the inner surface of the upper mold 26 as shown in FIG. 1. Specifically, the portion to which the reinforcing sheet 16 is attached is pressed against the mounting pin 28 of the upper mold 26, and the mounting pin 28 is pierced and penetrated through the reinforcing sheet 16 together with the stretchable nonwoven fabric 14, as shown in FIG. . In this case, the stretchable nonwoven fabric 14 alone is soft and has no waist, so it is difficult to wear it. However, since the reinforcing sheet 16 is superimposed on the penetrating portion, it can be worn stably.
[0018]
Next, as shown in FIG. 1, the foaming raw material 32 is injected from the injection device 30 into the recess of the lower mold 22, the upper mold 26 is closed, and the foam is hardened in the cavity. Thereafter, the upper mold 26 is opened and removed to obtain the seat cushion pad 10.
[0019]
As shown in FIGS. 3 and 4, the obtained seat cushion pad 10 is obtained by integrally forming a stretchable nonwoven fabric 14 on the back surface, and the stretchable nonwoven fabric 14 does not stretch even after integral molding impregnated with a foaming raw material. Therefore, there is no sense of incongruity or discomfort in terms of sitting comfort, and the stroke feeling and rebound feeling are excellent. Here, since the reinforcing sheet 16 is only provided in a part around the mounting pin 28, the characteristic of the stretchable nonwoven fabric 14 is not inhibited. 3 and 4 indicate marks of the mounting pins 28, that is, holes formed by the mounting pins 28 during foam molding.
[0020]
According to the present embodiment described above, the reinforcing sheet 16 is attached to the stretchable nonwoven fabric 14 at a planned penetration position of the mounting pin 28, and the stretchable nonwoven fabric 14 reinforced in this way is interposed via the mounting pin 28. Since it sets to the upper mold | type 26, since the handleability of the elastic nonwoven fabric 14 is improved and an operator's burden is eased, a mounting mistake can be reduced. Moreover, since the penetration part of the mounting pin 28 is reinforced by the reinforcing sheet 16, it is possible to prevent the stretchable nonwoven fabric 14 from coming off after being set, and to significantly reduce the defect rate and the repair rate.
[0021]
In the above embodiment, since the provided reinforcing sheet 16 on the surface of the pad body 12 side of the elastic nonwoven fabric 14, the reinforcing sheet 16 in the product state it is not exposed to the outside.
[0023]
【The invention's effect】
When a sheet pad producing method of the present invention, the through predetermined position of the mounting pin in the stretchable nonwoven fabric in advance to reinforce the said through scheduled position by the reinforcing sheet Ru provided as a reinforcing layer, reinforced in this way Since it is set in a foaming mold using an elastic nonwoven fabric, the burden on the operator is reduced, mounting errors are reduced, and the defect rate and repair rate due to the removal of the elastic nonwoven fabric can be greatly reduced. As a result, the cost can be reduced.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a foam mold according to an embodiment of the present invention.
FIG. 2 is an enlarged view of a main part of FIG.
FIG. 3 is a cross-sectional view of a seat cushion pad in the embodiment.
FIG. 4 is a bottom view of the seat cushion pad in the embodiment.
[Explanation of symbols]
10 ... Seat cushion pad 12 ... Pad body 14 ... Stretch nonwoven fabric 16 ... Reinforcement sheet (reinforcement layer)
20 …… Foaming mold 22 …… Lower mold 26 …… Upper mold 28 …… Mounting pin

Claims (1)

The stretchable nonwoven fabric is set on the inner surface of the upper mold of the foam mold comprising the lower mold and the upper mold, and the stretchable material is injected into the cavity of the foam mold to cause foaming. A method of manufacturing a pad for a sheet in which a nonwoven fabric is integrated,
A plurality of mounting pins are provided on the inner surface of the upper mold of the foaming mold so as to pass through predetermined portions of the stretchable nonwoven fabric and support the stretchable nonwoven fabric, and in the portion penetrated by the mounting pins in the stretchable nonwoven fabric. A reinforcing sheet made of a sheet material having a lower elasticity than the elastic nonwoven fabric is attached, and the portion of the reinforced elastic nonwoven fabric to which the reinforcing sheet is attached is connected to the surface on which the reinforcing sheet is attached to the cavity. The stretchable nonwoven fabric is set in the foaming mold by pressing against the mounting pin in a state of being directed to the side and passing the mounting pin through the reinforcing sheet together with the stretchable nonwoven fabric. A method for manufacturing a pad for a sheet.

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