JPH01262809A - Cushion body - Google Patents

Abstract

PURPOSE:To enhance the air permeability of the cushion body without degrading functions such as comfortableness to sit on and durability by using fibers having small fineness hence higher softness as a stock and constituting respective cushion layers of said fibers. CONSTITUTION:The fibers having <=50 denier, more preferably <=30 denier (<=30 denier in average in case of blended fibers which are different in fineness) are used as the stock. The fibers having <=50 denier are used as the spring rest cushion material which constitutes the lower layer part of the cushion body and plays the role of a spring rest function in order to maintain face rigidity and the durability to withstand the repetitive contact with springs. So called elastomers such as urethane prepolymers are used in a soln. type or emulsion type as the adhesive agent to be used for joining the fibers to each other. The respective fiber assemblies are packed in a metallic mold formed of a punching metal to a prescribed density and an urethane prepolymer is cured by steam. The molding is then parted from the mold. The cushion body which is laminated and integrally joined above and below with the cushion material 1 and the spring rest cushion body 2 having through-holes 3 is thereby obtd.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a cushion body used for vehicle seats, furniture chair seats, and the like.

[Conventional technology]

Cushion bodies for vehicle seats, furniture chair seats, etc.
In order to improve sitting comfort and durability, a hard layer of spring holder material is provided on the back, and a cushioning material is placed on top of this. This spring support is made of press-molded material such as palm rock material, and some are molded integrally with cushioning material, but generally this hard layer is highly dense, has low air permeability, and heats up easily. Because it is easy for moisture to get trapped,
For example, in the case of products that are used for long periods of time, such as car seats, there is a problem that comfort is reduced.Also, as a cushion material that also serves as a spring holder, for example, synthetic fiber filament molded seaweed is used as a cushioning material that also serves as a spring support. A cushioning material is formed by applying a chemical and bonding the contact points between filaments, and a material with a smaller fineness is placed in the upper layer and a material with a larger fineness is placed in the lower layer, and both are bonded together to form a cushion body ( However, these materials are made of fiber filaments that have a large fineness (50 to 1000 d) and are relatively hard.In particular, the lower layer cushion + which has the surface rigidity necessary for the spring receiver is Due to the high density, breathability is low, and problems remain with respect to comfort such as sitting comfort and durability.

[Problem to be solved by the invention]

Cushion bodies are required to have various functions and characteristics depending on the purpose and use of the seat.For example, in the case of cushion bodies for automobile seats, ① Sitting comfort (good body pressure I'1i and vibration characteristics); (Not too hard and has appropriate flexibility)
■Durability (less permanent deformation after repeated use)■
9. A wide range of functions are required, including breathability (not trapping heat or moisture and being comfortable to use for long periods of time or even in the summer), and moldability.

However, in such a cushioning body, it is difficult to maintain each of the above functions when the cushioning material layer is composed of a fiber aggregate made by binding hard fiber filaments with large fineness to each other with an adhesive. In addition, generally, this hard WJaall with a large fineness also leads to a decrease in the durability and moldability of the Kusongyong material.

Based on the above, in this invention, each cushion material layer is made of fibers with smaller fineness and therefore more flexibility, without comparably degrading the above-mentioned functions required for this type of cushion body. The aim is to obtain a cushion body that can improve its breathability.

[Means and effects for solving the problem] Based on the above, this invention first focuses on the synthetic fibers with a fineness of 50 deniers or less as the material of the cushion (e), and focuses on the synthetic fibers that intertwine with each other. A cushioning material in which crimped synthetic fibers are joined to each other at their intertwined portions, and a crimped synthetic fiber in the form of a consolidated sheet that is needled and provided with a plurality of through holes is joined to each other at their intertwined portions. It is characterized in that it consists of a spring-receiving cushioning material, and these are stacked up and down and both are integrally joined to form a cushion body.

That is, the cushioning material constituting the cushioning layer (including the upper middle layer and the lower layer) of the cushion body in this invention has appropriate flexibility to improve sitting comfort, and is also resistant to fraying, fading, etc. even with repeated use. In order to maintain durability and breathability, the material is made of fibers of 50 denier or less, preferably 30 denier or less (in the case of mixed fibers with different finenesses, the average is 30 denier or less),
In addition, the spring receiver cushion material, which constitutes the lower layer of the cushion body and in which the spring receiver plays a functional role, is made of
Use fibers of 0 denier or less. When providing a middle layer in addition to the upper layer as a cushioning layer, the cushioning material must be composed of fibers of 40 denier or less (in the case of mixed fibers with different finenesses, the average is 40 denier or less). is desirable. The fibers used as materials for the above cushioning materials are all synthetic fibers made of crimped short fibers, such as polyester, polypropylene, nylon, acrylic, vinylon, vinylidene, polyvinyl chloride, rayon, cupro, acetate, etc. It is also possible to use fibers by blending these synthetic fibers with natural fibers such as cotton, wool, and silk.

Furthermore, as the adhesive used to bond the fibers together, it is appropriate to use a so-called elastomer such as a urethane prepolymer in the form of a solution or emulsion type, or alternatively, a low melting point resin coated on the surface of the polyester fiber or the like. . It is also possible to use so-called fiber binders.

Therefore, the cushion material that constitutes the upper part of the cushion body is obtained by immersing a fiber aggregate selected from the above-mentioned fiber groups in a solution of an adhesive also selected from the above-mentioned groups, and then removing the excess adhesive. In order to do this, the mixture is centrifuged and the binder adhesion rate is adjusted to 25-35%.

Further, the spring receiving cushion material is produced by needling an aggregate of fibers similarly selected from the above fiber group to compact it into a sheet shape, and then punching a plurality of through holes in the sheet shape.

However, the above-mentioned needling process requires relatively strong needling, for example, the number of needles: 100, the number of punches: 600 times/min, and the feed rate in order to give the obtained sheet-like material the surface rigidity necessary for the spring bearing material. Apply speed: 1.5 m/min. Furthermore, after this two-drilling, the diameter of the holes to be drilled in the sheet-like material is 1 to 1, depending on the desired air permeability.
5 Using a n+m melting bottle or punch,
Pitch: Drill the required number of holes within the range of 3 to 20III11. It should be noted that the area ratio occupied by the perforations to the sheet-like material is appropriately in the range of 1 to 20%, and the relationship between this area ratio and the air permeability is as shown in Figure 3, when the area ratio is the same.
The smaller the pin, punch diameter, and pitch, the higher the air permeability can be obtained.

The perforated sheet material obtained in the above manner is cut into a predetermined shape, immersed in an adhesive solution and centrifuged to adjust the adhesion rate to 25 to 35% in the same manner as the cushion material.

As a cushion material forming the upper or lower layer of the cushion layer, each of the fiber aggregates that have gone through the above steps is filled into a mold made of punching metal and molded into one piece, thereby producing the materials shown in FIGS. 1 and 2. A cushion body having the structure shown in can be obtained.

Example 1 A mixed fiber assembly in which 38 denier ([1) crimped polyester staple fibers and 14 d crimped polyester staple fibers were mixed at a weight ratio of 1:1 was subjected to needling (number of needles: 100). / CD, number of punches 2,600 times /
min, feed speed: 1.5 m) L, [-1750 g/d to form a consolidated sheet (10 mm thick) with a web shape on one side. Next, using a punching device in which a large number of pins (diameter 3 mm) with built-in heaters are arranged at a pitch of lOmrs, the pins heated to 260 to 300°C (temperature between the melting point and decomposition point of polyester fiber) are inserted into the sheet. Apply it to an object and melt it to penetrate, and make the required number of through holes (diameter 3 mm,
(pitch loam interval). This perforated sheet material was cut into a predetermined shape, and urethane prepolymer with a concentration of 60% (Mitsui Toatsu Chemical, NGO-596 synthesized from MN3050 and T-80)/Tricene (Asahi Glass, 1,1. 1. After immersing in the trichloroethane solution, the binder adhesion rate is adjusted to 25-35-6 by centrifugation.

Next, a mixed fiber aggregate obtained by mixing 38 d of crimped polyester GU ti and (id of crimped polyester staple fibers) at a weight ratio of 1:1 was added to a 50% urethane prepolymer/Tricene solution. After immersing in water, the binder adhesion rate is adjusted to 25 to 3596 by centrifugation.

Each fiber aggregate treated as described above is filled into a mold made of punching metal to a predetermined density, and the urethane prepolymer is cured with steam and removed from the mold. As a result, a cushion body as shown in FIG. 1 is obtained in which the cushion material 1 and the spring receiving cushion material 2 having the through holes 3 are vertically stacked and joined together.

This cushion body has appropriate flexibility and constitutes a comfortable cushion layer with an extremely good surface feel without any discomfort such as unevenness or hardness, and is also durable. Further, the lower cushioning material 2 has sufficient surface rigidity as a spring bearing material, but is not hard, and together with the upper cushioning material 1 constitutes a cushion body that is stable both in shape and function. . The air permeability of the cushion body in which a large number of through holes 3 are provided in the lower cushion material 2 is extremely good as shown in the air permeability Al1j constant (based on JIS L 109B) results shown in FIG. In addition, air permeability can be improved by appropriately selecting the area ratio of the through holes 3 to the lower cushioning material 2 within a range that does not impair its surface rigidity.

Example 2 A crimped polyester short fiber aggregate of 38 d was needled under the same conditions as in Example 1 to obtain a fabric weight of 750 g.
/ry? Then, one side is formed into a consolidated sheet (thickness lOm+*) with a web shape. Then, using a punching device similar to that of the above embodiment, a pin heated to 260 to 400' C is applied to the sheet material to melt and penetrate the material to form the required number of through holes (diameter 3+om, pitch 1oIII). This sheet-like material was cut into a predetermined shape, and the concentration was 75%.
After dipping in the urethane prepolymer/Tricene solution, the binder adhesion rate is adjusted to 25 to 3506 by centrifugation. This sea!・After cutting the shaped article into a predetermined shape and immersing it in a urethane prepolymer/Tricene solution with a concentration of 75%, the binder adhesion rate is reduced to 25~25% by centrifugation.
Adjust to 35%.

Next, as a cushioning material for the middle layer, a mixed fiber aggregate was prepared by mixing 38 d of crimped polyester short fibers and 6 d of similarly crimped polyester short fibers at a weight ratio of 1:1.
After immersion in a urethane prepolymer/Tricene solution with a concentration of 50%, the binder adhesion rate is similarly adjusted to 25 to 35%. Further, as a cushioning material for the upper layer, a crimped polyester short iron fiber assembly a of 13d is immersed in a 45% urethane prepolymer/Tricene solution, and the binder adhesion rate is adjusted to 25 to 35%.

After each fiber aggregate treated as described above is filled into a mold made of punching metal to a predetermined density, water vapor is introduced to harden the urethane prepolymer and the mold is removed. As a result, as shown in Fig. 2, a cushion layer consisting of the two layers of cushioning material 1.1a is laminated on the lower spring receiving cushioning material 2, and each layer is integrally joined to form a three-layer structure. A cushion body similar in effect to Example 1 was obtained.

Example 3 A consolidated sheet-like material obtained by needling the same mixed fiber aggregate under the same conditions as in Example 1 was prepared using a large number of punches (diameter 3 mm) arranged at a pitch of 10 mm. Punch it out using a punching device to make the required number of holes. This was immersed in 6L of the same urethane prepolymer/Tricene solution as in Example 1, and then centrifuged to obtain an adhesion rate of 2.
Adjust to 5-35%. After impregnating the same mixed polyester fiber aggregate as in Example 1 with an adhesive, the adhesion rate was adjusted. The material treated as described above is packed into a mold at a predetermined density, and after the adhesive is cured, it is taken out.

The obtained cushion body has the same effect as the above example.

〔Effect of the invention〕

As described above, according to the present invention, it is possible to improve the breathability of the cushion body without impairing its sitting comfort or durability, thereby meeting almost all of the characteristics required of this type of seat cushion material. It is possible to provide a cushion body that satisfies the above requirements.

[Brief explanation of the drawing]

1 and 2 are vertical cross-sectional views schematically showing the structure of a cushion body according to an embodiment of the present invention, and FIG.
The figure also shows the relationship between air permeability and pore area ratio of a cushion body which is an embodiment of the present invention. Applicant's agent Patent attorney Takehiko Suzue 01 Figure 2 Completed PCT,> Figure 3

Claims (1)

[Claims] (1) A cushioning material in which crimped synthetic fibers that are intertwined with each other are joined to each other at their intertwined portions, and a crimped synthetic fiber that is needled and forms a consolidated sheet with a plurality of through holes, What is claimed is: 1. A cushion body comprising a spring receiving cushion material joined to each other at the upper and lower portions, and these materials are stacked one above the other and integrally joined.