JP4422856B2 - Cushion material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a cushion material used for automobile seats, bedding, furniture, building materials and the like.
[0002]
[Prior art]
Cushion materials are used to support complex curved surfaces such as the body as evenly as possible, in addition to the function of reducing vibration and shock. The present invention relates to the latter cushioning material for supporting the body. In this field, a futon wrapped around a fiber such as cotton and wrapped with a raw cloth is used in the past, and utilizes the elasticity of the fiber itself. In bedding and furniture, a three-dimensional structure is formed by spiraling or bending a steel wire to provide a planar cushioning material. In recent years, petrochemical products have become widespread, and foamed resin products have become the mainstream, realizing ease of molding, light weight, and low cost, and establishing an unwavering position. However, a product that provides a comfortable state by blowing warm air or cold air to the cushion material is desired, and since a foamed resin product is poor in air permeability, a new cushion material having good air permeability is desired. As a new cushion material using fibers, there is a three-dimensional knitted fabric using monofilaments by a double raschel machine, which provides products that are lightweight, breathable, and excellent in cushioning properties. However, there is a difficulty in terms of mass productivity and cost, and further improvement is required. The present invention is proposed in response to such a demand.
[0003]
[Problems to be solved by the invention]
An object of the present invention is to provide a planar cushion material having good air permeability utilizing the elasticity of a resin wire and / or a cylindrical material.
[0004]
[Means for Solving the Problems]
In the present invention, an elastic curved portion made of a resin wire and / or a resin cylinder exists between two sheets, and the curved portion is fixed to at least one of the sheet and / or another sheet. Molded integrally. The two sheets mentioned above refer to a surface covering material for adjusting the outer shape as a cushion or a sheet for the lining material, and includes another sheet in which a curved portion is fixed or integrally formed. A sheet for fixing or integrally molding the curved portion can serve as the two sheets. And more specifically, the situation where the curved portion having elasticity is fixed to or integrally formed with the sheet may be before or after the curved portion is formed, at the same time or after, or only the curved portion is separately formed. It is included in the present invention. As will be described later, when the curved portion is protruded from one sheet, the sheet and the curved portion are formed integrally, so that the curved portion forms a sheet, but the curved portion exists. There is no difference. The present invention includes a case in which one or two or more sheets having a curved portion fixed or integrally formed are present between the two sheets.
[0005]
As the resin wire, a material that can withstand repeated bending stress is used, but a form in which the resin wire is highly oriented by stretching is preferable. Examples of the resin include thermoplastic resins such as nylon, polyester, polypropylene, and polyethylene. The separation length of the two sheets may be in the range of 5 to 30 mm, but 9 to 12 mm is suitable as a cushioning material for the seat. Various methods are considered as a method of fixing the curved resin wire between the two sheets. As an example, the resin wire is heated and deformed by a heating roll having a tooth shape on the peripheral surface and fed between the sheets. The method of bonding and integrating and obtaining a cushioning material is mentioned. Since the resin cylinder itself has a curved portion on the peripheral surface, the cylinder cylinder itself is used as an elastic body, and the resin cylinder is used by rounding the resin wire. Further, as will be described later, the curved portion is directly projected from the sheet as a tape. Since it is used as an elastic material that can withstand repeated loads, it is preferably molded while expanding in the radial direction.
[0006]
The cushion material is used by sticking or quilting a surface material suitable for the application, but the surface material is required to be stretchable with respect to a load having a curved surface such as a human body. Accordingly, the cushion material is also required to have stretchability to follow the cover material. The bending portion of the resin wire or the resin tube material can be deformed so that the interval between the adjacent wires is widened while being bent with respect to the expansion and contraction of the cover material, so that the expansion and contraction of the cover material is not hindered.
[0007]
The resin wire is easily deformed by heating into a curved shape such as a monofilament or a tape. As the monofilament, 100 to 1000 denier is preferably used. Further, the shape of the tape is not particularly limited, but a tape having a width of 1 to 5 mm and a thickness of 0.1 to 1 mm is preferably used. As a guide, a 300-denier nylon filament that is curved to support body load is 1 cm. ² 20-30 per hit are required. The bending of the resin wire is easy to bend when a load is applied, and the elastic feel is soft. As the curvature radius of the curve increases, it becomes linear and the feel becomes harder, but it is also effective as a cushioning material to have hard touch parts mixed together, and such linear resin wires are mixed between sheets. A cushioning material comprising the above is also included in the present invention. Moreover, the cylinder body which has circular, an ellipse, and an irregular cross-sectional shape is used for the resin cylinder material. When the cylindrical body is cut into a ring shape or provided with an uncut part at the time of ring cutting and is extended in the axial direction and used in a state where the ring is connected, productivity at the time of fixing to the seat is improved. The monofilament can also be fixed between sheets using sewing means such as a sewing machine. In order to sew monofilaments simultaneously at close positions, the amount of yarn stored in the bobbin of the lower thread is limited in the main sewing method, and the chain stitching method using a compound needle is advantageous. Furthermore, the form which fixes a tape to a sheet | seat in uneven | corrugated bending form can also be shape | molded integrally with a sheet | seat using the extrusion type | mold provided with the tooth | gear type | mold. The portion extruded in the concavo-convex bent shape has a tape-like curved portion and is included in the resin wire of the present invention. The tape to be extruded in this way is not limited in width and thickness, but may have any shape that exhibits flexural elasticity. The monofilament and tape used in the present invention are not a tape when the width of the tape divided from the sheet is almost the same as the thickness of the sheet in addition to the commercially available monofilament. I have a good idea. Similarly, a tape has a flat shape having a width that is much larger than its thickness. In addition to a long tape obtained by slitting from a film, a portion that is divided into a predetermined length from a film is also regarded as a tape. It is made.
[0008]
Further, the resin wire is heat-molded into a ring shape or a spiral shape based on a circular, elliptical or irregular cross section, and fixed to at least one sheet by adhesion or heat fusion, or integrally molded with the sheet. The above-mentioned ring shape, spiral shape, and cylindrical shape are not necessarily limited to the state in which the peripheral surface is closed, but a composite cross section in which an opening exists in a part or combined with another resin wire or cylinder Shapes are also included in the present invention. For example, in the case of a resin wire, the resin wire may be formed by slitting a film or sheet into a tape shape, but the film or sheet is heat-molded into the above shape so as to partially have an opening without slitting. . Moreover, as for a cylindrical thing, the cylinder etc. which were extrusion-molded by the cross-sectional shape which the surrounding surface of the cylinder overlapped and the semicircle and the circle were integrated can be illustrated. In the present invention, a curved portion exists between two sheets, but a shape in which the curved portion exists in a part and the remaining part connected to the curved part is also included is included. The resin wire formed integrally with the sheet forms a tape protruding from the sheet using a pressing die and a receiving die. In addition, two sets of pressing molds and receiving molds are prepared, and a sheet is fed into each to form a protruding tape. Before the protruding tape is released from the pressing mold, both protruding portions are heated and pressed against the tape. Can be provided with a bulky cushioning material since a cushioning material having a tape curved in two steps can be obtained.
[0009]
Furthermore, the monofilament and / or tape is formed to protrude from the sheet in a convex and / or concave shape with a predetermined length and width using a pressing mold and a receiving mold, and the remaining portion of the sheet that is not projected is curved and By forming a linear rib, the rib is deformed or moved in the same plane in at least one of vertical, horizontal, and diagonal directions when receiving a load. The deformation or movement of the rib means that the cushion material expands and contracts, and when one curved portion is deformed by receiving a load, the amount of displacement acts so as to push the adjacent curved portion. It expands and contracts. In addition, the ribs described above can be created in any way by the arrangement of the remaining portion of the seat, so that the ribs are easily deformed by forming a rib extending linearly in a curved line or oblique direction, and the entire cushion material can be expanded and contracted in all directions. I did it.
[0010]
Further, a tape formed by protruding a predetermined length in a convex and / or concave shape from a sheet having a portion having a different thickness, and the remaining portion of the non-projected sheet forms a curved and / or linear rib and protrudes. The amount of displacement or extension with respect to stress is controlled by associating the portion with different thickness with the portion of the rib that does not protrude. For example, if the thick part of the sheet is made to correspond to the part connected to the rib of the tape formed so as to correspond to the part having a small thickness gradually toward the protruding tape, it will concentrate on the base of the tape due to repeated loading. In addition to giving sufficient load resistance to the load, the elasticity of the tape can be controlled. Further, even in the above ribs, a rib having a large thickness is difficult to be deformed, but a portion having a small thickness is easily deformed. A thermoplastic resin is used for the sheet, and examples thereof include nylon, polyester, polypropylene, and polyethylene.
[0011]
A curved portion having elasticity formed into a ring shape, a spiral shape, a concave-convex bent shape, or a cylindrical shape is appropriately mixed on the sheet or between the sheets according to the use site or purpose of the cushion. For example, under the condition that two sheets are kept at the same interval, a resin wire formed in a ring shape and a spiral shape and a resin wire extending in one direction bent in a concavo-convex shape using the same tape are used. When arranged in parallel, the former shows strong elasticity in the extending direction, while the latter shows weak elasticity in the central axis direction. Further, since the latter tends to be longer with respect to the length of the rising portion of the former resin wire and the latter, the latter is more elastic with respect to the vertical load. On the other hand, when a cylindrical member is used, sufficient stretching cannot be performed in the circumferential direction as in the case of a resin wire, but the repulsive force tends to become harder by approximating a state where the spiral winding density is dense. Therefore, when these curved portions having various forms are mixed, a cushioning material rich in functionality can be provided by utilizing the respective properties.
[0012]
Furthermore, at least one of the two sheets is made of a plastic material, the plastic material is molded into a flat plate or a curved surface according to demand, and the molded resin wire is adhered thereon, and the plastic material or flexible material is attached to the upper surface. A cushioning material that conforms to the shape of the plastic material is provided by adhering various sheets. The plastic material means a material that remains deformed even when an external force is removed, and includes a resin and a metal material. Since such a plastic material is used as a part of the structural material, it can be applied to automobile seats and the like, and it is effective in reducing the material and reducing the weight.
[0013]
In addition, the sheet has a breathable structure such as a net cloth, a nonwoven fabric, a raw cloth, a knitted fabric, and a breathable structure such as a resin film in which holes are fitted. Is done. It is more advantageous in terms of recycling that the sheet is made of the same resin as the resin wire or cylinder.
[0014]
On the other hand, in order to facilitate the work in the secondary processing such as the functionality of the entire cushion or sewing, the portions where the intervals between the two sheets are different are mixed. The portion where the interval is different includes the case where two sheets are in close contact with each other. When receiving a physical load, a massage effect can be obtained if the cushion material is scattered in height. In order to obtain such a structure, if the heating roll used when bending the resin wire is divided, each roll has a gear shape with different tooth heights, and these are used as parallel rolls. Can be obtained. In the case of a ring-shaped or spiral resin wire and a cylindrical material, those different in outer shape may be prepared and appropriately arranged. If the thickness of the end portion of the cushion material is gradually reduced and a portion not using the resin wire material is provided at the final end portion, the workability is good and the finish is excellent when stitching with other members.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
[Example 1]
FIG. 1A shows a first embodiment of the present invention and is a perspective view of a cushion material 1. As a resin wire 2 for developing elasticity, after extruding a nylon resin, a tape material having a width of 3 mm and a thickness of 0.2 mm is stretched and bent into a concavo-convex shape by thermoforming, as shown in FIG. Curve. The resin wire is bonded and fixed between the two sheets 3 so that the convex portions 2b and the concave portions 2c of the resin wire are alternately positioned. A nonwoven fabric made of nylon fibers was used as the sheet. Vent holes 4 are fitted into the sheet 3 at a predetermined interval, and in addition to the breathability of the nonwoven fabric itself, further breathability is improved. Various shapes are used for the bent shape of the resin wire, but in the case of the resin wire 5 having the shape shown in FIG. 1B, the four curved rising portions 5a, 5b, 5c, and 5d cooperate to generate a vertical load. In addition to the above, since it exhibits strong elasticity against a load applied from an oblique direction, even if the width of the resin wire is 2 mm, it shows a property that it is difficult to fall down against the load.
[0016]
Next, the manufacturing method and apparatus of the cushion material 1 described above will be described with reference to FIG. A sheet 3 is moved by a pair of pressure-bonding rolls 6 and 6a. 7 and 7a are coating apparatuses which apply the adhesive 8 by a roll, and can apply the adhesive to one side of the sheet. On the other hand, the stretched resin wire 9 is sent out to the thermoforming rolls 11 and 11a by a feed roll 10 at a constant speed. When this thermoforming roll has a tooth mold on its peripheral surface and meshes, the resin wire is bent into an uneven shape and sent to the guide 12. The heating means is performed by irradiating the peripheral surface of the thermoforming roll with infrared rays, but preheating is also applied to the resin wire to maintain the roll surface at the softening temperature of the resin. The heat-molded resin wire is cooled when passing through the guide 12, and the rear portion 12a of the guide has an action of maintaining the posture of the resin wire until the resin wire is fixed on the sheet. When the arrangement of the concave and convex shapes of the resin wire fixed between the sheets is alternately shifted, the path lengths of the guides 12 may be different. The structure of the guide is a comb shape composed of a combination of a side plate and a bottom plate, and is used after being subjected to chromium plating or fluororesin coating from the viewpoint of reducing the friction coefficient of the surface and wear resistance. In this example, the resin wire is bonded to the sheet 3 using a non-woven fabric, but may be heat-sealed using a thermoplastic resin film instead of the non-woven fabric. In the case of a resin film as well, air holes are fitted at predetermined intervals to supplement air permeability, but the area of the hole that is blocked is small even if the resin wire is located in the air hole. The diameter of the air hole is preferably 1 to 3 mm, and the length is selected so that the resin wire does not fall off. If the pitch of the air holes is small, it is no longer a net, and if a net is used instead of the seat, the air permeability is further improved and the cushioning property is also flexible. The belt conveyor 13 is used for the conveyance after the resin wire is bonded by the pressure-bonding roll 6, but a belt conveyor 14 is further provided on the upper portion in order to ensure the bonding. Thus, the cushion material 1 can be obtained continuously. Although it has been described that a thin tape-shaped resin wire is used, it is also included in the present invention that a stretched film is slit in the stretching direction to be used as a thin tape, and a monofilament can be used instead of the tape. is there. Further, if the height of the tooth molds of the thermoforming rolls 11 and 11a is reduced, the height of the rising portion 2a of the bent resin wire is reduced, so that portions having different thicknesses can be scattered in one cushion material. As it can, it can give a massage effect when supporting the body, and if the thickness is gradually reduced at the end of the cushioning material and a part without the resin wire is formed, a sewing machine hook is used when sewing other members to the end It becomes easy.
[0017]
[Example 2]
Next, another shape of the resin wire will be described. FIG. 3A shows an example in which a plurality of helical resin wires 15 are arranged in parallel and bonded to the sheet 3. The basic shape in the direction of the central axis of the spiral is a circle or an ellipse, and the circle or ellipse arc is fixed as a curved portion between the sheets. An irregular cross-sectional shape can be used similarly. In this example, a nonwoven fabric was used for the sheet. The sheet provided on the upper surface is not shown because it is the same as that on the lower surface. The resin wire 15 is a nylon monofilament, preferably 200 to 1000 denier, and 300 denier was used in this example. The outer shape of the spiral and the winding pitch of the wire are not particularly limited, but are determined according to the denier number depending on the cushioning properties required for each application. As a cushioning material for the seat, when 300 denier of nylon 66 is used as the resin wire, the outer diameter of the spiral is 9 to 10 mm, and the winding pitch is 1 mm as a guide. Such a helical resin wire 15 is bonded to the concave portion of the sheet 3 in which the arc-shaped concave portion 16 is preliminarily thermoformed, and is adhered using the pressure rolls 6 and 6a shown in FIG. If the interval between the recesses 16 is set such that the resin wires overlap each other, the number of resin wires per unit area can be increased. Further, a vent hole 4 is provided in advance in the sheet to ensure further air permeability. The spiral resin wire is molded in advance and inserted parallel to the moving direction of the nonwoven fabric (the direction of arrow A). Even if the winding pitch is 1 mm, adjacent wire rods may not overlap with each other accurately, but there is no influence on cushioning properties because the spiral portion exists almost uniformly as a whole. FIG. 3B shows an example in which the plastic material 17 is used for the sheet on one side and the sheet 3 is used for the other side. As the plastic material, a thermoplastic resin plate is mainly used, and it is molded into a plate having a curved surface according to demand. The plate having this curved surface can be used as a structural material as it is. Metal plates such as aluminum and iron are also a kind of plastic material. In this example, in order to form portions having different thicknesses of the cushion material, those having different spiral winding diameters are used, and if the resin wire is omitted, the thickness of the cushion is only the thickness of the seat.
[0018]
[Example 3]
FIG. 4 shows an example using a right-handed resin wire 18 and a left-handed resin wire 18a in which a nylon 66 drawn tape is spiraled. The ribbon material has a width of 2 mm and a thickness of 0.2 mm. The spiral winding pitch of the tape is 5 mm, the feeding amount is accurately performed, and the winding directions are arranged so as to be different from each other so that adjacent wires are easy to interlace with each other, so that the density of the resin wire is increased. Can do. In this case, the right-handed and left-handed wires act to support each other not only with respect to the vertical weight but also with an oblique load, so that they are hard to fall down and show strong elasticity. The sheet may be a non-woven fabric or a resin film, but in this example, a netting 19 is used. The material constituting the mesh is not particularly limited, but the mesh size is selected so that the spiral resin wire does not fall off, and the mesh pitch is also matched to the spiral winding pitch. In the case of a mesh, when a load is applied, the mesh deforms so that the mesh spreads. Therefore, the deformation of the mesh and the deformation of the resin wire material combine to increase the effective sinking amount for the load.
[0019]
[Example 4]
FIG. 5A shows a ring 20 in which a cylindrical tube made of a resin film is cut and arranged on a sheet 3, and a sheet on one side is not shown. However, since it is difficult to arrange the rings continuously in a sheet shape, the length of the ring cutting is made long and cylindrical, and this may be used as an elastic body for the load applied directly in the radial direction. However, as shown in FIG. 5 (b), a part of the cylindrical tube described above is left as the uncut portions 21a and 21b, and the connected ring 20a obtained by repeating these is pulled in the direction of the central axis. Adhering and fixing on the groove 16 provided in the sheet 3. The ring is fixed to the seat surface by inclining alternately in different directions, and exhibits elasticity that has the property of not easily falling down in the axial direction of the ring. A cushioning material is obtained by adhering a sheet to the upper surface of the ring rows adjacent to each other with the pitch shifted and arranged in parallel. Furthermore, as shown in FIG. 5 (c), if the resin cylinder 22 has different thicknesses T1 and T2 and is used for the cushion, the elastic range that can be dealt with even if the load fluctuates is widened. Although the above description is about a cylinder, the cross-sectional shape of the cylinder is not limited to a circle or an ellipse, and the cross-sectional shape of the cylinder is not limited to a round shape. The cylindrical body 22a, the cylindrical body 22b in which the curved portion and the straight portion are integrally formed as shown in FIG.
[0020]
[Example 5]
FIG. 6 (a) shows that a pressing part having a tooth shape and a receiving mold corresponding to this are pressed against the thermoplastic resin film 23 to form protrusions while heating, and the rising curved parts 24a and 24b are integrated with the film. Molded. The curved portion is formed into a square shape while being stretched, and forms a kind of tape, and is regarded as a resin wire. Since the upper surface 24c of the convex portion is adhered or fused to the cover material sheet, the curved portion exhibits elasticity with respect to the load. A hole is formed in the extruded portion of the film, and the film is used as the vent hole 4a. If the cushion material has a relatively small area, it is possible to obtain a molded product having the shape shown in FIG. 6A by placing the pressing die and the receiving die in close proximity in parallel and pouring resin into the gap. . The shape of the curved portion that forms the protruding portion is not limited to this example, and includes one that includes only the curved portion from which the upper surface of the convex portion is omitted. An arc shape, a waveform, etc. can be illustrated. If a knitted fabric having elasticity is bonded to the upper surface of such a curved tape protruding on one side, a cushion material having a curved portion between two sheets can be obtained. As another method, as shown in FIG. 2 (b), two sets of pressing molds and receiving molds are arranged, the sheet is fed into each of them, and the curved portion is projected, while the sheet is released from each pressing mold. Two sheets can be obtained by releasing the both sides of the sheet after fusing a part of each sheet by bringing the convex part of the pressing die on one side into contact with the convex part or concave part on the other side through the sheet before the sheet is attached. The cushion material which connected the curved part between 23 can be obtained. FIG. 2B is a diagram in which the upper surface 24c of the convex portion is fused by pressing the convex portion of the pressing die against the convex portion on the other side. A bulky cushion can be obtained.
[0021]
[Example 6]
FIG. 7 shows another example of Example 5, in which protruding curved portions are alternately formed on both sides of the film. FIG. 7A shows the curved portions 24a, 24b, 24d, and 24e that are alternately projected from the film 23. FIG. The portions that do not protrude are arranged so as to be continuous, and as a result, the ribs 25 that extend long are formed. When the load is received, the above-described curved portions act to bulge and press the rib 25, so that the cushion material extends in the direction perpendicular to the long rib. FIGS. 7B to 7F show the projecting portion of FIG. 7A as a plan view. (B) In the figure, the rib 25 is a straight line and cannot be expected to extend in the direction of the straight line. On the other hand, the rib 25 extends in an oblique direction in FIG. 5 (c), and in FIG. 4 (d), the rib 25 is deformed in a direction in which the rib becomes a straight line. Shrink when returning to the original shape. The form in which the curved portion is integrally formed with the seat as described above can also be regarded as a single cushion sheet, and if a plurality of these are stacked, a cushion material with a larger sinking amount can be obtained. .
[0022]
[Example 7]
An example in which the protruding portion is created from the sheet using sheets having different thicknesses will be described. FIG. 8A is a partial cross-sectional view of sheets 40 having different thicknesses. Reference numeral 40a denotes a portion having a large thickness and a portion which later becomes a rib. Reference numeral 40b denotes a portion having a small thickness and forming a protruding portion. Figure (b) shows a tape 40c that is extruded from the sheet 40a using a mold to form a tape 40c, and a tape 40e that protrudes on the opposite side is formed at an adjacent position. The remaining portion 40a that does not protrude becomes a rib. Is shown. In this example, the rib is thick and the tape is thin, but the connecting portion 40d is thicker than the tape, and when the tape is bent under load, the concentrated load is applied to the portion 40d, so that it can be reinforced. Furthermore, if the thickness of the sheet is determined so that the tape becomes thinner as it approaches the protruding peak, the cushion feel can be controlled to be initially soft and gradually hardened. Further, as shown in FIG. 4C, when the curved tape 40c receives the load P, the rib 40a is displaced in the direction of flattening, and the curved tape is about to extend. The cushion material as a whole will stretch. Accordingly, it is possible to appropriately control the amount of displacement and extension of the curved tape by making the rib thicker or thinner depending on the purpose of use.
[0023]
[Example 8]
FIG. 9 shows another embodiment, and shows a method of sewing resin wires. (A) In the figure, the two sheets 26a and 26b are separated by the guide 27a, the guide 27b is arranged on the upper surface of the sheet 26a, and the lower surface of the sheet 26b is supported by the plate 28 so that the two sheets are parallel to each other. Move in the direction of arrow B. The guide has a form in which a large number of plate pieces are vertically arranged in parallel at predetermined intervals. The plate 28 is provided with a hole 29, and the composite sewing needle 30 penetrates obliquely with a predetermined angle with respect to the seat surface. The composite sewing needle 30 is composed of two elements, and a sliding needle 30b that slides along the sewing needle body so as to close a sewing needle body 30a having a sharp tip and a threading hole 31 provided near the tip of the sewing needle body. A plurality of compound sewing needles are arranged in parallel at a predetermined interval and fixed to a bar to form a needle row. The yarn introduction piece 32 is adapted to rotate the tip of the sewing needle body in order to put the monofilament 33 on the threading hole 31 described above. When such a device is used, the composite sewing needle 30 moves up and down in an oblique direction, and when the sheet is moved in the direction of arrow B in synchronization with the vertical movement of the sewing needle, a chain stitch is formed on the two sheets. The chain stitch forms a loop 33a on the sheet surface on one side and a main seam 33b on the sheet surface on the other side. Since it is a chain stitch, two monofilaments 33d are sewn in a curved shape between the sheets.
[0024]
(B) The figure is performed following the process of (a), but the composite sewing needle 30 moves up and down in different directions to form a similar ring stitch, but the monofilament 33e sewn between the sheets is at a different angle. Fixed. (C) The figure is a side view showing a fixed state of the monofilament and the sheet obtained through the above two steps, and a resin is applied to the outer side surface to fix the seam to obtain a cushioning material. If the composite sewing needle is moved up and down in three directions, the monofilament is arranged in the shape of a triangular pyramid, so that it exhibits elasticity that does not easily collapse with respect to the load.
[0025]
【The invention's effect】
According to the present invention, since the resin wire that has been stretched to enhance the restoring force against bending is fixed in a curved shape between the predetermined length sheets, the elastic feel is soft and durable, and the lightweight and cushioning material is breathable. Can be provided. Since the curved resin wire has various forms as described above and can be combined easily, a portion that exhibits elasticity different in properties can be formed in one cushion material, so that the function according to the application can be configured. A highly cushioning material can be provided. A curved resin wire can provide the same effect even with a tubular material. Although the elasticity in the radial direction of the tubular material itself is used, if it is used as a ring shape by cutting it into a ring, the air permeability can be improved. Further, if a tape is produced by projecting from a sheet using sheets having different thicknesses, the strength of the cushion can be freely imparted. It is also used for the seat as a cushioning material that can be air-conditioned through warm air or cold air between the seats. The resin wire is simply deformed with a heating roll and is simply bonded and fixed to a sheet or net, and is excellent in productivity. Although the present invention has been described as a cushioning material, it can be installed without gaps even when the gaps between the portions to be inserted are uneven as part of the wall material of the house.
[Brief description of the drawings]
FIG. 1A is a perspective view of a cushion material in which a tape-shaped resin wire is bent into a concavo-convex shape and a sheet is bonded to both surfaces, and FIG. 1B is a perspective view showing another shape of the resin wire.
FIG. 2 is an explanatory view showing a method of manufacturing a cushion material according to the present invention.
FIG. 3A is a perspective view showing another embodiment in which a monofilament is spirally bonded as a resin wire and a sheet is bonded, and FIG. 3B is an example using a plastic material having a curved surface on one side of the sheet. It is a perspective view shown.
FIG. 4 is a perspective view showing another embodiment in which a tape is spirally used as a resin wire.
5A is a perspective view showing an example using an independent ring-shaped resin wire, and FIG. 5B is a perspective view showing an example of a continuous ring-shaped resin wire obtained by connecting a part of the ring. It is. (C) is a perspective view which shows another shape of the resin cylinder used as a raw material. (D) And (e) is a perspective view which shows the example of a deformed cross section.
6A is a perspective view showing an example of a resin wire extruded from a sheet and formed with a rising portion, and FIG. 6B is a perspective view of a cushion material in which two sets of curved portions are joined.
FIG. 7A is a perspective view showing an example of a resin wire rod that protrudes from a sheet in a convex and / or concave shape for a predetermined length to form a rising portion, and FIGS. 7B to 7F show an array of protruding portions. It is a plane explanatory view.
8A is a partial cross-sectional view of a sheet having portions with different thicknesses, FIG. 8B is a cross-sectional view of a protruding curved portion, and FIG. 8C is a curved portion deformed by receiving a load. It is a schematic cross section which shows this state.
9A shows a method of fixing a resin wire to a sheet using a sewing needle, FIG. 9B is an explanatory view showing a subsequent process, and FIG. 9C is a cushion obtained by this method. It is composition explanatory drawing of material.
[Explanation of symbols]
1 Cushion material of the present invention
2 Resin wire
3 sheets
4,4a Vent
5 Resin wire
6 Crimp roll
7 Coating device
8 Adhesive
9 Resin wire
10 Feeding roll
11 Thermoforming roll
12 Guide
13,14 belt conveyor
15 Spiral resin wire
16 recess
17 Plastic material
18 Spiral resin wire
19 Netting
20 rings
21 Uncut part
22 cylinder
24 curved tape
25 ribs
27 Guide
30 Compound sewing needle
32 Yarn guide
33 Monofilament
40 Sheet with different thickness

Claims (3)

The resin wire is a tape formed by projecting a predetermined length from the resin sheet into a convex shape and a concave shape, and the curved portion having elasticity is formed by heating , and the curved portion is arranged so as to be positioned between two other sheets. Then, a portion of the curved portion is fixed, and the remaining portion of the sheet that is not projected forms a curved and / or linear rib, and when receiving a load, the curved portion bends to generate elasticity , A cushion material, wherein the rib is deformed or moved in at least one of vertical, horizontal, and diagonal directions. The resin wire is a tape, and is formed to protrude from a sheet having a portion having a different thickness in a convex and concave shape for a predetermined length, and the remaining portion of the non-projected sheet forms a curved and / or linear rib and protrudes. The cushion material according to claim 1, wherein the amount of displacement and the amount of elongation with respect to stress are controlled by appropriately matching the portions having different thicknesses with the formed ribs and the ribs of the portions that do not protrude. The cushion material according to claim 1 or 2, wherein at least one of the two sheets to which a part of the curved portion is fixed has a ventilation structure.

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