JPH02286225A - Production of skinned expandable pad - Google Patents
Production of skinned expandable padInfo
- Publication number
- JPH02286225A JPH02286225A JP1106825A JP10682589A JPH02286225A JP H02286225 A JPH02286225 A JP H02286225A JP 1106825 A JP1106825 A JP 1106825A JP 10682589 A JP10682589 A JP 10682589A JP H02286225 A JPH02286225 A JP H02286225A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- resin
- sheet
- skin sheet
- impregnated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 59
- 239000000463 material Substances 0.000 claims abstract description 25
- 239000006260 foam Substances 0.000 claims abstract description 20
- 239000004840 adhesive resin Substances 0.000 claims abstract description 14
- 229920006223 adhesive resin Polymers 0.000 claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 12
- 239000004744 fabric Substances 0.000 claims abstract description 11
- 238000010030 laminating Methods 0.000 claims abstract description 5
- 239000010985 leather Substances 0.000 claims abstract description 5
- 239000002985 plastic film Substances 0.000 claims abstract description 4
- 239000000835 fiber Substances 0.000 claims abstract description 3
- 230000002093 peripheral effect Effects 0.000 claims description 5
- 238000003466 welding Methods 0.000 claims description 5
- 239000012209 synthetic fiber Substances 0.000 claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims description 3
- 238000005187 foaming Methods 0.000 abstract description 18
- 229920005989 resin Polymers 0.000 abstract description 11
- 239000011347 resin Substances 0.000 abstract description 11
- 239000007788 liquid Substances 0.000 abstract description 9
- 230000037303 wrinkles Effects 0.000 abstract description 7
- 238000007665 sagging Methods 0.000 abstract description 4
- 238000005304 joining Methods 0.000 abstract description 3
- 239000011248 coating agent Substances 0.000 abstract description 2
- 238000000576 coating method Methods 0.000 abstract description 2
- 230000001105 regulatory effect Effects 0.000 abstract 1
- 230000000694 effects Effects 0.000 description 7
- 238000007666 vacuum forming Methods 0.000 description 6
- 238000000034 method Methods 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- 239000002759 woven fabric Substances 0.000 description 4
- -1 Polypropylene Polymers 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229920000915 polyvinyl chloride Polymers 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- 239000004831 Hot glue Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 239000011094 fiberboard Substances 0.000 description 2
- NNPPMTNAJDCUHE-UHFFFAOYSA-N isobutane Chemical compound CC(C)C NNPPMTNAJDCUHE-UHFFFAOYSA-N 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 239000002562 thickening agent Substances 0.000 description 2
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 241000282320 Panthera leo Species 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 125000005396 acrylic acid ester group Chemical group 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 235000011114 ammonium hydroxide Nutrition 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000012752 auxiliary agent Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229920006026 co-polymeric resin Polymers 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 238000010097 foam moulding Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 239000001282 iso-butane Substances 0.000 description 1
- 239000002649 leather substitute Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000003981 vehicle Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【発明の詳細な説明】
（産業上の利用分野）
この発明は、椅子のシート、背もたれ、車両用内装材お
よび衣服用キルテイング地等に好適なかわ張り発泡パッ
ドの製造法に関するものである。DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a foam pad suitable for chair seats, backrests, interior materials for vehicles, quilted fabrics for clothing, and the like.
（従来の技術）
椅子のシート、背もたれ、乗用車の内装材、アタッシュ
ケースやトランクの内貼り材としてハードボードやファ
イバーボード等の板状基材上にポリプロピレン、ポリエ
チレン、ポリ塩化ビニル。(Prior technology) Polypropylene, polyethylene, and polyvinyl chloride are applied to plate-shaped substrates such as hardboard and fiberboard for use as seat and backrests of chairs, interior materials for passenger cars, and lining materials for attaché cases and trunks.
ポリウレタン等のフオームパッドを積層し、その上を布
帛やレザー等の可どう性表皮シートで被覆したものが、
また衣服や寝具用クツションとして表裏の布帛間に上記
のフオームパッドを挟み、キルテイングにより一体化し
たものが使用されている。また、上記のフオームパッド
の代りに、合成繊維のフィラメントからなる不織布のフ
ィラメントおよびその交絡部を、独立気泡を有する熱可
塑性樹脂発泡体で被覆してなる弾性パッドを使用するこ
とが知られている（実開昭６３−１２４１２２号公報参
照）。Foam pads such as polyurethane are laminated, and the top is covered with a flexible skin sheet such as fabric or leather.
In addition, cushions for clothing and bedding are used in which the above-mentioned foam pad is sandwiched between front and back fabrics and integrated by quilting. In addition, instead of the above-mentioned foam pad, it is known to use an elastic pad made by covering nonwoven fabric filaments made of synthetic fiber filaments and their intertwined portions with a thermoplastic resin foam having closed cells. (Refer to Utility Model Application Publication No. 124122/1983).
（発明が解決しようとする課題）
しかしながら、従来は、上記のフオームパッドや弾性パ
ッドを発泡処理後のかさ高な状態で任意の基材と表皮シ
ートとの間に積層していたので、積層体の周縁を高周波
ウェルダや縫合によって仕上げたり、キルテイング状の
模様を形成したりする場合に上記の積層体を周縁やキル
テイング模様線に沿って圧縮しなければならず、この圧
縮が面倒で、十分な圧縮ができなかったり、そのため立
体感が不足したり、また表皮シートの張りが不十分にな
って見苦しい皺が生じたりする等の問題があった。そし
て、上記のフオームパッドや弾性パッドに立体感のすぐ
れたキルテイング状の凹凸模様を付すためには、注型発
泡を必要とし、そのためには金型その他の設備を用意し
なければならなかった。また、積層体中のパッドが発泡
済みのものであるため、かさ張りが大きく１発泡工程か
ら積層工程への搬送や取扱いが不便であった。(Problem to be Solved by the Invention) However, in the past, the foam pad or elastic pad described above was laminated between an arbitrary base material and a skin sheet in a bulky state after foaming, so the laminate When finishing the periphery using high-frequency welding or stitching, or when forming a quilted pattern, the above-mentioned laminate must be compressed along the periphery or quilting pattern line, and this compression is troublesome and requires sufficient There were problems such as not being able to be compressed, resulting in a lack of three-dimensional effect, and insufficient tension in the skin sheet, resulting in unsightly wrinkles. In order to give the above-mentioned foam pads and elastic pads a quilted pattern with excellent three-dimensional effect, casting foaming is required, and for this purpose, molds and other equipment must be prepared. Furthermore, since the pads in the laminate are already foamed, they are bulky and are inconvenient to transport and handle from the first foaming step to the lamination step.
この発明は、積層終了後または製品組立後に発泡を行な
うことにより、周縁の仕上げ、キルテイング模様の形成
を容易にし、キルテイング等による凹凸模様の立体感を
増大し、表皮シートの張りを良好にして皺の発生を防止
し、かつ金型の使用を不要にしたものである。This invention makes it easier to finish the periphery and form a quilted pattern by foaming after the completion of lamination or product assembly, increases the three-dimensional effect of the uneven pattern created by quilting, improves the tension of the skin sheet, and eliminates wrinkles. This prevents the occurrence of this problem and eliminates the need for a mold.
（課題を解決するための手段）
上記の課題を解決するため、この発明においては、任意
繊維のフィラメントからなる不織布に未膨張のマイクロ
バルーンが含まれた接着性樹脂液を含浸し乾燥して上記
不織布を構成するフィラメントおよびその交絡部を上記
の接着性樹脂液で被覆し、得られた樹脂含浸不織布に布
帛や皮革またはプラスチックシートなどの可とう性の表
皮シートを積層し、得られた積層シートの少なくとも周
縁部を縫合、高周波ウェルダ、挟圧等の締め付け手段に
よって締め付け該締め付け部に位置するマイクロバルー
ンの膨張力を減殺またはそう失させた状履下で上記積層
シートを加熱し、その締め付け部以外のマイクロバルー
ンを膨張させ樹脂含浸不織布をかさ高に形成する。(Means for Solving the Problems) In order to solve the above problems, in the present invention, a nonwoven fabric made of filaments of arbitrary fibers is impregnated with an adhesive resin liquid containing unexpanded microballoons and dried. The filaments constituting the nonwoven fabric and their intertwined parts are coated with the above-mentioned adhesive resin liquid, and a flexible skin sheet such as fabric, leather, or plastic sheet is laminated onto the resin-impregnated nonwoven fabric, resulting in a laminated sheet. The laminated sheet is heated under a condition in which at least the peripheral edge of the sheet is tightened by a tightening means such as sutures, high-frequency welding, or pinching, and the expansion force of the microballoon located at the tightened portion is reduced or lost, The other microballoons are expanded to form a bulky resin-impregnated nonwoven fabric.
上記の不織布、を構成するフィラメントは、ポリエステ
ル系、ポリアミド系、ポリアクリル系、ポリ塩化ビニル
系、ポリオレフィン系等の合成繊維フィラメント、およ
びガラス、カーボン等の無機質繊維フィラメントである
が、合成繊維、特に加熱により巻縮を発現する潜在巻縮
性のフィラメントが好ましい、なお、上記フィラメント
の好ましい繊度は、１．０デニ一ル以上、特に５．０デ
ニ一ル以上１０．０デニール以下であり、細過ぎると製
品のバルキー性が不十分になる。The filaments constituting the above-mentioned nonwoven fabric include synthetic fiber filaments such as polyester, polyamide, polyacrylic, polyvinyl chloride, and polyolefin, and inorganic fiber filaments such as glass and carbon. Latent crimp filaments that develop crimp when heated are preferred. The preferred fineness of the filaments is 1.0 denier or more, particularly 5.0 denier or more and 10.0 denier or less; If it is too high, the bulkiness of the product will be insufficient.
上記のフィラメントは、これをランダムに配列してウェ
ブとし、このウェブを目付量が例えば５０〜１５０ｇ／
ｒｒｒとなるように重ね、フィラメント相互の接触部を
熱接着、好ましくはパウダーボンディングで固着するこ
とにより不織布に形成される。The above filaments are randomly arranged to form a web, and the web has a basis weight of, for example, 50 to 150 g/
A nonwoven fabric is formed by stacking the filaments so that the filaments are rrr, and fixing the mutually contacting portions by heat bonding, preferably powder bonding.
なお、ニードルパンチングによりフィラメント相互を絡
合して不織布に形成することができるが、この場合は、
マイクロバルーンの加熱発泡時にフィラメント相互の絡
合部にずれが生じる程度に針密度を粗くすることが好ま
しい。Note that filaments can be entangled with each other to form a nonwoven fabric by needle punching, but in this case,
It is preferable to make the needle density coarse enough to cause displacement of the intertwined portions of the filaments during heating and foaming of the microballoon.
上記の不織布に含浸される接着性樹脂液は、熱可塑性の
接着剤用樹脂、増粘剤および助剤がらなり、これにマイ
クロバルーンを配合し、攪拌して得られ、１００〜１８
０’Ｃの加熱により上記マイクロバルーンの膨張による
独立気泡を生じるものである。なお、マイクロバルーン
は、ポリ塩化ビニル、ポリ塩化ビニリデン、ポリアクリ
ロニトリル等のガスバリヤ性を有する樹脂のいずれか１
種または２種以上の共重合樹脂からなり、イソプロパン
、イソブタン等のガスを封入したものである。The adhesive resin liquid impregnated into the above-mentioned nonwoven fabric consists of a thermoplastic adhesive resin, a thickener, and an auxiliary agent, and is obtained by blending microballoons therewith and stirring.
By heating at 0'C, the microballoon expands to form closed cells. Note that the microballoon is made of any one of resins with gas barrier properties such as polyvinyl chloride, polyvinylidene chloride, and polyacrylonitrile.
It is made of a seed or a copolymer resin of two or more types, and is filled with a gas such as isopropane or isobutane.
このマイクロバルーンと接着性樹脂固型分の好ましい配
合比は、８０／２０〜９９／１であり、特に９０／１０
〜９６／４が好ましく、マイクロバルーンの配合比が少
ないと発泡倍率が不足して反発弾性が低下し、反対に多
過ぎると接着性樹脂液の接着力が不足して加工性が悪く
なる。The preferred blending ratio of the microballoon and the solid adhesive resin is 80/20 to 99/1, particularly 90/10.
A ratio of 96/4 to 96/4 is preferable; if the blending ratio of the microballoons is too low, the expansion ratio will be insufficient and the impact resilience will be lowered, while if it is too high, the adhesive strength of the adhesive resin liquid will be insufficient and processability will deteriorate.
上記の接着性樹脂液は、上記の不織布に浸漬、塗布、ス
プレー等の手段によって含浸させ、必要に応じて絞り、
好ましくは含浸量（固形分付量）を不織布重量の２０〜
１００％、好ましくは４０〜７０％に調節して乾燥し、
上記不織布を構成するフィラメントおよびその交絡部を
上記の接着性樹脂で被覆する。The above-mentioned adhesive resin liquid is impregnated into the above-mentioned nonwoven fabric by means such as dipping, coating, spraying, etc., and if necessary, the adhesive resin liquid is squeezed.
Preferably, the impregnation amount (solid content amount) is 20 to 20% of the weight of the nonwoven fabric.
Dry at 100%, preferably 40-70%,
The filaments constituting the nonwoven fabric and their intertwined portions are coated with the adhesive resin.
得られた樹脂含浸不織布の表面に重ねられる表皮シート
は、織物、編物、皮革、プラスチックシート等の可とう
性シートであり、所望により、上記樹脂含浸不織布の裏
面に上記と同様の可どう性シート、またはハードボード
、ファイバーボード、パイプ等からなる任意形状の基材
を重ねることができる。The skin sheet superimposed on the surface of the obtained resin-impregnated nonwoven fabric is a flexible sheet such as woven fabric, knitted fabric, leather, plastic sheet, etc. If desired, a flexible sheet similar to the above is placed on the back side of the resin-impregnated nonwoven fabric. Alternatively, base materials of arbitrary shapes such as hardboard, fiberboard, pipes, etc. can be layered.
上記の表皮シートおよび樹脂含浸不織布は、積層され、
好ましくは高周波ウェルダまたは縫合によってその少な
くとも周縁部に沿って接合され、更に必要に応じて中央
部をキルテイングの模様状に接合され、接合部分に位置
するマイクバルーンが破壊されるか、またはマイクロバ
ルーンの発泡が生じない程度に締め付けられる。なお１
表皮シートおよび樹脂含浸不織布の二者を重ね、貼合せ
。The above skin sheet and resin-impregnated nonwoven fabric are laminated,
Preferably, the microballoons are joined along at least their peripheral edges by high-frequency welding or suturing, and if necessary, the central part is joined in a quilting pattern, and the microballoon located at the joint is destroyed or the microballoon is Tighten to the extent that foaming does not occur. Note 1
The skin sheet and resin-impregnated nonwoven fabric are layered and laminated together.
その他の任意の手段で接合し、この重合シートを任意形
状の基材、好ましくは板材やパイプ等からなる構造材に
被着し、重合シートの少なくとも周縁部を上記基材に接
合して接合部分に位置するマイクロバルーンが破壊され
るか、またはマイクロバルーンの発泡が生じない程度に
締め付けることができる。The polymer sheet is bonded by any other means, and the polymer sheet is adhered to a base material of any shape, preferably a structural material such as a plate or pipe, and at least the peripheral edge of the polymer sheet is bonded to the base material to form a bonded portion. The pressure can be tightened to such an extent that the microballoon located in the microballoon is not destroyed or foaming of the microballoon occurs.
次いで、上記の表皮シート、樹脂含浸不織布および基材
の積層体は、オーブンに入れられ、スチームヒータ、′
赤外線ヒータ、高周波誘電加熱等により１００〜１８０
℃で０．５〜５．０分間加熱され。Next, the laminate of the skin sheet, resin-impregnated nonwoven fabric, and base material is placed in an oven and heated with a steam heater.
100 to 180 using infrared heater, high frequency dielectric heating, etc.
℃ for 0.5-5.0 minutes.
これにより樹脂含浸不織布中のマイクロバルーンが発泡
し、樹脂含浸不織布がかさ高性を発現する。As a result, the microballoons in the resin-impregnated nonwoven fabric foam, and the resin-impregnated nonwoven fabric exhibits bulkiness.
この場合、オーブンの加熱温度は、樹脂含浸不織布中の
接着性樹脂の融点よりも高く設定される。In this case, the heating temperature of the oven is set higher than the melting point of the adhesive resin in the resin-impregnated nonwoven fabric.
なお、表皮シートとして熱可塑性シートを用い。In addition, a thermoplastic sheet was used as the skin sheet.
この熱可塑性シートの表皮シートと樹脂含浸不織布とを
、好ましくは両者間に熱可塑性樹脂フィルム等のホット
メルト接着剤を介在させて重ね、この重合シートを真空
成型用の金型に上記の表皮シートが金型凹部に面するよ
うに取付けてその周縁部を上型で抑圧固定して周縁部に
位置するマイクロバルーンの発泡が生じない程度に締め
付け、この状態下で重合シートの真空成型を行なうこと
ができる。The skin sheet of this thermoplastic sheet and the resin-impregnated nonwoven fabric are laminated, preferably with a hot melt adhesive such as a thermoplastic resin film interposed between the two, and this polymerized sheet is placed in a mold for vacuum forming. Attach it so that it faces the mold recess, press and fix its periphery with the upper mold, tighten it to the extent that the micro balloons located at the periphery do not foam, and perform vacuum forming of the polymerized sheet under this condition. I can do it.
（作用）
積層体をオーブン中で加熱することにより、不織布の構
成フィラメントを被覆する発泡性樹脂中のマイクロバル
ーンが膨張し、フィラメント相互の接着部や交絡部にず
れが生じて樹脂含浸不織布がかさ高性を発現し、積層体
の表皮シートおよび基材の内面に圧力が加えられ１表皮
シートおよび可どう性シート製の基材が膨張し、かわ張
り発泡パッドが製造される。得られたかわ張り発泡パッ
ドの充填材は、ガスの逃げ場がないマイクロバルーンの
独立気泡を有する発泡合成樹脂および不織布で形成され
るので、連続気泡を有する通常の発泡合成樹脂、または
独立気泡であってもマイクロバルーンを有しない発泡樹
脂をパッドに用いたものに比べて圧縮抵抗が増大し、圧
縮率が低下し、底づき感が解消する。そして５表皮シー
トを積層。(Function) By heating the laminate in an oven, the microballoons in the foamable resin that covers the constituent filaments of the nonwoven fabric expand, causing displacement of the mutually bonded and intertwined parts of the filaments, causing the resin-impregnated nonwoven fabric to become bulky. The material exhibits high properties, and pressure is applied to the inner surfaces of the skin sheet and base material of the laminate to inflate the skin sheet and the base material made of the flexible sheet, producing a sticky foam pad. The filling material of the obtained stiff foam pad is made of foamed synthetic resin and non-woven fabric that have micro-balloon closed cells from which there is no place for gas to escape. However, compared to a pad made of foamed resin without microballoons, the compression resistance increases, the compression ratio decreases, and the feeling of bottoming out is eliminated. Then, 5 skin sheets are laminated.
接合後に発泡させるので１表皮シートおよび可とう性シ
ート製の基材が発泡に伴う内圧によって四方に緊張され
、たるみや皺が伸ばされる。しかも。Since foaming is performed after bonding, the skin sheet and the flexible sheet base material are tensed in all directions by the internal pressure accompanying the foaming, and sagging and wrinkles are smoothed out. Moreover.
縫合や高周波ウェルダその他の締め付けによって線状に
接合され、発泡機能を失なった部分は、かさ高性を全く
発現しないで、発泡前の状態に保持されるので、かさ高
性発現部分との凹凸差が顕著に表われる。更に、目的に
応じてマイクロバルーンの充填密度を調整することによ
り、製品の空隙率、圧縮弾性率および圧縮率を容易に設
定することができる。The parts that are linearly joined by sutures, high-frequency welding, or other tightening methods and have lost their foaming function do not exhibit any bulkiness and are maintained in their pre-foaming state, so there is no unevenness between them and the parts that exhibit bulkiness. The difference is noticeable. Furthermore, by adjusting the packing density of the microballoon according to the purpose, the porosity, compressive elastic modulus, and compressibility of the product can be easily set.
なお、不織布を潜在巻縮性フィラメントで製造した場合
は、発泡のための加熱処理によってフィラメントが巻縮
を発現するので、かさ高性が更に増大する。また、加熱
処理の際に表皮シートの真空成形を同時に行なうと、金
型の形状に応じて表皮シートに凹凸が成型されると共に
、樹脂含浸不織布中のマイクロバルーンが部分的に大き
さの異なる膨張をして上記金型の内部空間を満たす形状
の発泡パッドが得られ、この場合に上記の表皮シートと
樹脂含浸不織布との間にあらかじめホットメルト接着剤
をフィルムの形で介在させたときは、真空成型と同時に
両者が接着して一体化される。In addition, when the nonwoven fabric is manufactured using latent crimp filaments, the filaments develop crimp due to the heat treatment for foaming, so that the bulkiness is further increased. In addition, if the skin sheet is vacuum-formed at the same time as the heat treatment, unevenness will be formed on the skin sheet depending on the shape of the mold, and the microballoons in the resin-impregnated nonwoven fabric will partially expand to different sizes. A foam pad having a shape that fills the inner space of the mold is obtained, and in this case, when a hot melt adhesive is interposed in advance in the form of a film between the skin sheet and the resin-impregnated nonwoven fabric, At the same time as vacuum forming, the two are bonded and integrated.
（実施例）
不織布として、潜在巻縮性ポリエステルフィラメントか
らなる目付量１０８ｇ／ｒｒｆの熱融着不織布（ローア
ンド・ボナー社製、商品名「ウルトラロフトＬＰ１０８
Ｊ）を用いた。一方、マイクロバルーン（松本油脂製薬
株式会社製、商品名「松本マイクロスフェアＦ ３０Ｊ
） ９４．５重量部、接着用の酢酸ビニル・エチレン
共重合体エマルジョン（住友化学工業株式会社製、商品
名「スミカフレックス７５３Ｊ）５重量部、アクリル酸
エステル系増粘剤（互応化学工業株式会社製、商品名「
Ｄ２５１Ｊ）０．５重量部および少量のアンモニア水を
混合して粘度を５００ＣＰに調整し、得られた濃度２０
％の水溶液を発泡性樹脂液とした。(Example) As a nonwoven fabric, a heat-sealable nonwoven fabric with a basis weight of 108 g/rrf made of latent crimpable polyester filament (manufactured by Lowe & Bonner, trade name "Ultraloft LP108") was used.
J) was used. On the other hand, a microballoon (manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd., product name "Matsumoto Microsphere F 30J"
) 94.5 parts by weight, 5 parts by weight of vinyl acetate/ethylene copolymer emulsion for adhesion (manufactured by Sumitomo Chemical Co., Ltd., trade name "Sumikaflex 753J"), acrylic acid ester thickener (manufactured by Gooh Chemical Co., Ltd.) Manufactured by, product name:
D251J) 0.5 parts by weight and a small amount of ammonia water were mixed to adjust the viscosity to 500CP, resulting in a concentration of 20
% aqueous solution was used as the foamable resin liquid.
この発泡性樹脂液に上記の熱融着不織布を浸漬し、ニッ
プロールに通して絞り、絞り率３００％。The heat-sealable nonwoven fabric was immersed in this foamable resin liquid and squeezed through nip rolls to obtain a squeezing rate of 300%.
ウェット重量４００ｇ／ｒｆに調整し、この樹脂含浸不
織布をオーブンに入れ、６５℃で乾燥した。この乾燥さ
れた樹脂含浸不織布は、厚さＩＩ、重量１７０ ｇ ／
−であった。The wet weight was adjusted to 400 g/rf, and the resin-impregnated nonwoven fabric was placed in an oven and dried at 65°C. This dried resin-impregnated nonwoven fabric has a thickness of II and a weight of 170 g/
-It was.
上記の樹脂含浸不織布を織布製基材と編物製表皮シート
との間、および織布製基材と織布製表皮シートとの間に
それぞれサンドインチ状に挟み、キルテイング加工を施
し、しかるのち１２０℃のオーブン中で２分間加熱した
ところ、マイクロバルーンが発泡し、かつ不織布の構成
フィラメントが巻縮を発現し、キルテイングによる縫合
部の厚さ１ 、 Ｏｒｍ、膨張部分の厚さ１０．０ｕｎ
の鮮明な立体感を有し、クツション性にすぐれ、外観の
美しい、かつ底づき感のないクツション材が得られ、自
動車の室内クツション材として好適であった。The above resin-impregnated nonwoven fabric is sandwiched between a woven fabric base material and a knitted fabric skin sheet, and between a woven fabric base material and a woven fabric fabric skin sheet, respectively, and quilted. When heated in an oven at 120°C for 2 minutes, the microballoon foamed, the constituent filaments of the nonwoven fabric developed crimping, and the thickness of the quilted stitched part was 1.0 mm, and the thickness of the expanded part was 10.0 un.
A cushioning material with a clear three-dimensional effect, excellent cushioning properties, a beautiful appearance, and no feeling of bottoming out was obtained, and was suitable as an interior cushioning material for an automobile.
また、上記の乾燥された樹脂含浸不織布の上にラッシェ
ル編地の表皮シートを貼合せ、この貼合せシートを用い
て乗用車の座席の背もたれの大きさの袋を作り、背もた
れのフレームを基材として上記の袋を被着し、袋の口部
をフレーム下端部に鋲で固定し、発泡処理のみを残した
形で製品化し、しかるのちオーブン中で１２０℃、２分
間の熱処理を行なったところ、上記袋の縫製時にコーナ
部等に生じた皺が消え、膨らみが増大し、立体感に富み
、意匠性に優れた背もたれが得られた。In addition, a skin sheet of Raschel knitted fabric was laminated onto the dried resin-impregnated nonwoven fabric, and a bag the size of a passenger car seat back was made using this laminated sheet, and the backrest frame was used as a base material. The above bag was attached, the opening of the bag was fixed to the lower end of the frame with rivets, and the product was manufactured with only the foaming treatment remaining, and then heat treated in an oven at 120°C for 2 minutes. The wrinkles generated at the corners and the like during the sewing of the bag disappeared, the bulge increased, and a backrest with a rich three-dimensional effect and excellent design was obtained.
次に、上記の乾燥された樹脂含浸不織布の表面に熱可塑
性合成樹脂からなる厚さ１．ｏｍｍの合皮シートを表皮
シートとして貼合せ、この重合シート（幅６５ｍ、長さ
３１０１１１１）を真空成型用の最大深さ４０ｉｓの凹
みを有する金型上に、上記表皮シートを下に向けて置き
、金型を閉じて樹脂含浸不織布の裏面に平坦な」−型を
当接し、かつ重合シートの周縁を圧着により締め付け固
定し、しかるのち上記の金型を加熱しながら金型内を減
圧して表皮シートを金型の形状に真空成形すると共に、
樹脂含浸不織布中のマイクロバルーンを膨張させて上記
不織布を金型の空間形状に成形し、しかるのち成型品を
取出して上記不織布を含む発泡パッドの裏面を基板に貼
合せた。Next, the surface of the dried resin-impregnated nonwoven fabric is coated with a thermoplastic synthetic resin to a thickness of 1. Omm synthetic leather sheet was laminated as a skin sheet, and this polymeric sheet (width 65 m, length 3101111) was placed on a mold having a recess with a maximum depth of 40 is for vacuum forming, with the skin sheet facing down. , the mold is closed, a flat mold is brought into contact with the back side of the resin-impregnated nonwoven fabric, and the peripheral edge of the polymerized sheet is tightened and fixed by pressure bonding, and then the pressure inside the mold is reduced while heating the mold. Along with vacuum forming the skin sheet into the shape of the mold,
Microballoons in the resin-impregnated nonwoven fabric were expanded to mold the nonwoven fabric into the spatial shape of a mold, and then the molded product was taken out and the back side of the foam pad containing the nonwoven fabric was attached to a substrate.
（発明の効果）
この発明は、接着性樹脂を含浸した樹脂含浸不織布を表
皮シートと積層し、はぼ製品の形態が整えられた後に加
熱して発泡性樹脂に独立気泡を４”じさせる方法である
から、従来の発泡処理後に積層し、接合して製品の形態
に整える方法に比べて、積層、接合の作業が容易であり
、かつ表皮シートが発泡に伴なう内部圧力により緊張さ
れて皺やたるみが解消し、製品の外観が美しくなり、か
つ積層時にキルテイング模様を形成すると、凹部と凸部
の差が大きい立体感に優れた凹凸模様が得られる。そし
て、不織布に潜在巻縮性フィラメントを用いた場合は５
発泡処理の際に上記フィラメントが巻縮性を発現して製
品のかさ高性が一層増大する。また、樹脂含浸不織布お
よび表皮シートの積層シートを加熱する際、表皮シート
の真空成型を同時に行なうことにより、樹脂含浸不織布
の発泡成型を同時に行なうことができ、従来、発泡性ウ
レタン液を用いた場合は表皮シートの真空成型後に更に
発泡性ウレタン液の注型を必要としたのに比べて成型工
程が半減する。(Effects of the Invention) This invention is a method in which a resin-impregnated nonwoven fabric impregnated with an adhesive resin is laminated with a skin sheet, and after the shape of the habo product is adjusted, it is heated to form closed cells in the foamable resin. Therefore, compared to the conventional method of laminating and joining after foaming to form a product, the work of laminating and joining is easier, and the skin sheet is not tensed by the internal pressure that accompanies foaming. Wrinkles and sagging are eliminated, the appearance of the product becomes beautiful, and when a quilting pattern is formed during lamination, a textured pattern with excellent three-dimensional effect with a large difference between concave and convex parts is obtained.In addition, the nonwoven fabric has latent crimpability. 5 when using filament
During the foaming process, the filaments exhibit crimpability, further increasing the bulkiness of the product. In addition, when heating a laminated sheet of resin-impregnated nonwoven fabric and skin sheet, by vacuum forming the skin sheet at the same time, foam molding of the resin-impregnated nonwoven fabric can be performed at the same time. The molding process is halved compared to the case where a foaming urethane solution was required to be cast after the vacuum molding of the skin sheet.
特許出願人 東洋クロス株式会社 豊田通商株式会社 代理人 弁理士 吉 １）了 司Patent applicant: Toyo Cross Co., Ltd. Toyota Tsusho Corporation Agent: Patent Attorney Yoshi 1) Tsukasa Ryo
Claims (1)
のマイクロバルーンが含まれた接着性樹脂液を含浸し乾
燥して上記不織布を構成するフィラメントおよびその交
絡部を上記の接着性樹脂液で被覆し、得られた樹脂含浸
不織布に布帛や皮革またはプラスチックシートなどの可
とう性の表皮シートを積層し、得られた積層シートの少
なくとも周縁部を縫合、高周波ウェルダ、挟圧等の締め
付け手段によって締め付け該締め付け部に位置するマイ
クロバルーンの膨張力を減殺またはそう失させた状態下
で上記積層シートを加熱し、その締め付け部以外のマイ
クロバルーンを膨張させ樹脂含浸不織布をかさ高に形成
することを特徴とするかわ張り発泡パッドの製造法。 〔２〕樹脂含浸不織布を表皮シートと任意の基材との間
に積層する請求項１記載のかわ張り発泡パッドの製造法
。 〔３〕樹脂含浸不織布および表皮シートの積層シートで
袋を形成し、この袋を任意形状の基材に被着することに
より、樹脂含浸不織布を表皮シートと基材との間に積層
する請求項２記載のかわ張り発泡パッドの製造法。 〔４〕樹脂含浸不織布および表皮シートの積層シートを
加熱する際、表皮シートの真空成型を同時に行なう請求
項１記載のかわ張り発泡パッドの製造法。 〔５〕不織布が加熱により巻縮を発現する潜在巻縮性合
成繊維フィラメントで形成される請求項１ないし４のい
ずれかに記載のかわ張り発泡パッドの製造法。[Scope of Claims] [1] A nonwoven fabric made of filaments of arbitrary fibers is impregnated with an adhesive resin solution containing unexpanded microballoons and dried, and the filaments constituting the nonwoven fabric and their intertwined portions are bonded together as described above. The resulting resin-impregnated nonwoven fabric is then laminated with a flexible skin sheet such as fabric, leather, or plastic sheet, and at least the peripheral edge of the resulting laminated sheet is sewn, high-frequency welding, pinching, etc. Heating the laminated sheet under a condition in which the expansion force of the microballoons located at the tightening portion is reduced or lost by the tightening means of the tightening means, and the microballoons other than the tightening portion are expanded to make the resin-impregnated nonwoven fabric bulky. A method for producing a sticky foam pad characterized by forming a foam pad. [2] The method for producing a sticky foam pad according to claim 1, wherein the resin-impregnated nonwoven fabric is laminated between the skin sheet and any base material. [3] A bag is formed from a laminated sheet of a resin-impregnated nonwoven fabric and a skin sheet, and the bag is attached to a base material of an arbitrary shape, thereby laminating the resin-impregnated nonwoven fabric between the skin sheet and the base material. 2. The method for producing a sticky foam pad according to 2. [4] The method for producing a sticky foam pad according to claim 1, wherein when heating the laminated sheet of the resin-impregnated nonwoven fabric and the skin sheet, the skin sheet is vacuum-formed at the same time. [5] The method for producing a sticky foam pad according to any one of claims 1 to 4, wherein the nonwoven fabric is formed of a latent crimpable synthetic fiber filament that develops crimp when heated.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1106825A JPH0688353B2 (en) | 1989-04-26 | 1989-04-26 | A method of manufacturing foam pad |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1106825A JPH0688353B2 (en) | 1989-04-26 | 1989-04-26 | A method of manufacturing foam pad |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH02286225A true JPH02286225A (en) | 1990-11-26 |
| JPH0688353B2 JPH0688353B2 (en) | 1994-11-09 |
Family
ID=14443550
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1106825A Expired - Lifetime JPH0688353B2 (en) | 1989-04-26 | 1989-04-26 | A method of manufacturing foam pad |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0688353B2 (en) |
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0671065A (en) * | 1992-04-10 | 1994-03-15 | Yoshikazu Yamaguchi | Cushion material and manufacture thereof |
| WO2009119033A1 (en) * | 2008-03-28 | 2009-10-01 | 中川産業株式会社 | Process for producing heat-expandable base for interior vehicular trim and process for producing base for interior vehicular trim from the same |
| JP2009248305A (en) * | 2008-04-01 | 2009-10-29 | Shirogane Kasei Kk | Laminated sheet |
| CN102672966A (en) * | 2012-05-17 | 2012-09-19 | 常熟英提尔汽车饰件有限公司 | Coating process for automotive soft knee protection plate |
| JP2014012407A (en) * | 2009-02-06 | 2014-01-23 | Nike Internatl Ltd | Thermoplastic nonwoven fabric composite constituent |
| JP2014173221A (en) * | 2013-03-12 | 2014-09-22 | Boxmark Leather Proizvodnja In Trgovina Doo | Multilayer coating material for comfort furniture, including upholstery, cushion, blanket, etc. and production method thereof |
| US8906275B2 (en) | 2012-05-29 | 2014-12-09 | Nike, Inc. | Textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements |
| US9579848B2 (en) | 2009-02-06 | 2017-02-28 | Nike, Inc. | Methods of joining textiles and other elements incorporating a thermoplastic polymer material |
| US11779071B2 (en) | 2012-04-03 | 2023-10-10 | Nike, Inc. | Apparel and other products incorporating a thermoplastic polymer material |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS53127563A (en) * | 1977-04-13 | 1978-11-07 | Nippon Musical Instruments Mfg | Molding of synthetic resin with surface skin material |
| JPS63124122U (en) * | 1987-02-07 | 1988-08-12 | ||
| JPS63132718U (en) * | 1987-02-24 | 1988-08-30 |
-
1989
- 1989-04-26 JP JP1106825A patent/JPH0688353B2/en not_active Expired - Lifetime
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS53127563A (en) * | 1977-04-13 | 1978-11-07 | Nippon Musical Instruments Mfg | Molding of synthetic resin with surface skin material |
| JPS63124122U (en) * | 1987-02-07 | 1988-08-12 | ||
| JPS63132718U (en) * | 1987-02-24 | 1988-08-30 |
Cited By (19)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0671065A (en) * | 1992-04-10 | 1994-03-15 | Yoshikazu Yamaguchi | Cushion material and manufacture thereof |
| WO2009119033A1 (en) * | 2008-03-28 | 2009-10-01 | 中川産業株式会社 | Process for producing heat-expandable base for interior vehicular trim and process for producing base for interior vehicular trim from the same |
| JP2009234232A (en) * | 2008-03-28 | 2009-10-15 | Nakagawa Sangyo Kk | Process for manufacturing thermal expandable substrate for vehicle interior trim, and process for manufacturing substrate for vehicle interior trim using the same |
| JP2009248305A (en) * | 2008-04-01 | 2009-10-29 | Shirogane Kasei Kk | Laminated sheet |
| US10131091B2 (en) | 2009-02-06 | 2018-11-20 | Nike, Inc. | Methods of joining textiles and other elements incorporating a thermoplastic polymer material |
| US9732454B2 (en) | 2009-02-06 | 2017-08-15 | Nike, Inc. | Textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements |
| US10982363B2 (en) | 2009-02-06 | 2021-04-20 | Nike, Inc. | Thermoplastic non-woven textile elements |
| US10982364B2 (en) | 2009-02-06 | 2021-04-20 | Nike, Inc. | Thermoplastic non-woven textile elements |
| US9227363B2 (en) | 2009-02-06 | 2016-01-05 | Nike, Inc. | Thermoplastic non-woven textile elements |
| US9579848B2 (en) | 2009-02-06 | 2017-02-28 | Nike, Inc. | Methods of joining textiles and other elements incorporating a thermoplastic polymer material |
| US9682512B2 (en) | 2009-02-06 | 2017-06-20 | Nike, Inc. | Methods of joining textiles and other elements incorporating a thermoplastic polymer material |
| JP2014012407A (en) * | 2009-02-06 | 2014-01-23 | Nike Internatl Ltd | Thermoplastic nonwoven fabric composite constituent |
| US10625472B2 (en) | 2009-02-06 | 2020-04-21 | Nike, Inc. | Methods of joining textiles and other elements incorporating a thermoplastic polymer material |
| US10138582B2 (en) | 2009-02-06 | 2018-11-27 | Nike, Inc. | Thermoplastic non-woven textile elements |
| US10174447B2 (en) | 2009-02-06 | 2019-01-08 | Nike, Inc. | Thermoplastic non-woven textile elements |
| US11779071B2 (en) | 2012-04-03 | 2023-10-10 | Nike, Inc. | Apparel and other products incorporating a thermoplastic polymer material |
| CN102672966A (en) * | 2012-05-17 | 2012-09-19 | 常熟英提尔汽车饰件有限公司 | Coating process for automotive soft knee protection plate |
| US8906275B2 (en) | 2012-05-29 | 2014-12-09 | Nike, Inc. | Textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements |
| JP2014173221A (en) * | 2013-03-12 | 2014-09-22 | Boxmark Leather Proizvodnja In Trgovina Doo | Multilayer coating material for comfort furniture, including upholstery, cushion, blanket, etc. and production method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0688353B2 (en) | 1994-11-09 |
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