JPH05130923A - Molded reinforcing cloth for cushion material - Google Patents

Abstract

PURPOSE:To efficiently produce the exact reinforcing cloth with a single stage by continuously molding a nonwoven fabric having a shape complying with the shape of the cushion material consisting of a foamed resin integrally with the cushion material, thereby reinforcing the fabric. CONSTITUTION:The back rest of a chair or seat having three-dimensional intricate shapes is formed of the cushion material 5 consisting of the foamed resin. The reinforcing cloth 1 is molded integrally with the production of the cushion material 5. The nonwoven fabric consisting of thermoplastic fibers, such as acrylic or polyester is used for the reinforcing cloth 1. The shape thereof has a back part 2, a turned back part 4, penetration holes 3 of an additive member 6, etc., and is made to comply with the shape of the cushion material 5. As a result, the reinforcing cloth is continuously and integrally produced efficiently by fewer tools with the single stage and the generation of defective parts is prevented.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforcing cloth for a cushion material used for a seat surface, a back surface, etc. of a chair. More specifically, the present invention relates to a back cushion material for a back cushion material that reinforces the back surface of the back cushion material having a through hole for attaching an additional member such as a headrest facing the support member side.

[0002]

2. Description of the Related Art For example, in a backrest of a vehicle seat, a cushion member is mounted on a supporting member such as a pipe frame, and additional members such as a headrest are mounted.

FIG. 2 is a perspective view showing an example of a vehicle seat.

The cushion material 5 made of a resin foam or the like formed in a desired shape has a front surface covered with cloth or leather, and the back surface side thereof is attached to a support member (not shown) to support the backrest 8. Is forming.

A through hole 3 is formed in the cushion material 5 as required, and a leg of an additional member 6 such as a headrest is inserted therein, whereby the additional member 6 is effectively supported by a supporting member. It has become so.

At least a part of the back surface of the cushion member 5 facing the support member is in contact with the support member and rubs against the support member due to motion of the vehicle or movement of the user's body. . Therefore, conventionally, a reinforcing layer is provided on the back surface of the cushion material 5.

Since the reinforcing layer protects the cushion material 5 from wear and tear, it is so-called integral with the cushion material so as not to be displaced or separated from the cushion material 5. Preferably for that reason
During foam molding of the cushion material 5 made of resin foam,
For example, a method may be employed in which a resin is injected into the mold in a state where a reinforcing cloth is set on the inner surface of the mold in advance, and foaming is performed to simultaneously form the cushion material 5 and the reinforcing layer.

However, the back surface of the cushion material 5 on which the reinforcing layer is to be formed has a complicated curved surface.

For example, in the cushioning material 5 of the vehicle backrest 8 shown in FIG. 2, both side portions of the cushioning material 5 project toward the user in comparison with the central portion on the surface facing the user's back, and the upper body of the user's body is extended. It is typical to have a shape that holds The cushion material 5 has a shape in which both sides of the back portion 2 on the back surface are deeper toward the user than the central portion.

Further, at the mounting position of the additional member 6 such as a headrest, the through hole portion 3 communicating from the back surface to the front surface is formed, and the through hole portion 3 must also be provided with a reinforcing layer.

Further, since the upper portion of the cushion member 5 has a shape that extends backward beyond the support member, the folded-back portion 4 is also formed on the back surface side.

FIG. 3 is a longitudinal sectional view of the backrest 8 shown in FIG. 2 taken at the position of the through hole 3.

As described above, the back surface has the back portion 2 which is recessed toward the front surface particularly below the side portion, the through hole portion 3 for mounting the additional member 6 such as a headrest, and the folding portion 4 which wraps around the rear portion. And resin foam 7 around it
Is located.

When the cushion material having such a complicated shape is foam-molded by the method of simultaneously forming the reinforcing layer on the back surface as described above, the reinforcing cloth is formed on the inner surface of the mold having the same complicated shape as the back surface shape of the cushion material. Etc. will have to be set in advance.

Conventionally, as a back surface reinforcing cloth of a back cushion material having a through hole for attaching an additional member, in order to conform to a complicated shape, a non-woven fabric and a large number of small pieces of gold width are sewn so as to conform to the shape. What is joined by is used.

However, such a conventional reinforcing cloth requires a lot of labor and time for cutting and sewing, and nevertheless, it is difficult to obtain a reinforcing cloth that accurately matches the inner surface shape of the mold. Have. In addition to such insufficient shape accuracy, since the reinforcing cloth itself does not have the property of maintaining the shape, many fixing tools such as pins are required when mounting on the inner surface of the mold, and many sets are required for the set. It has the drawback of requiring labor and time. Furthermore, when a woven cloth such as a gold cloth is used as the reinforcing layer and integrally formed by resin foaming, sufficient adhesion between the foamed layer and the woven cloth cannot be obtained, resulting in insufficient shape accuracy. As a result, there is also a problem that a cushion material having a desired shape cannot be obtained and a molding defect is likely to occur.

[0017]

SUMMARY OF THE INVENTION The present invention has been made in view of the problems of the above-mentioned conventional back surface reinforcing cloth for a back cushion material, and is easy to manufacture, has good shape accuracy, and can be mounted on the inner surface of a mold. An object of the present invention is to provide a reinforcing cloth for a cushioning material, which is easy and has good adhesiveness with a resin foam and can significantly reduce the occurrence of defective formation.

[0018]

According to the present invention, a cushion material for reinforcing the surface of a cushion material, which is produced by molding a non-woven fabric having moldability into a shape conforming to the shape of the cushion material. A shaped reinforcement fabric is provided.

[0019]

The reinforcing cloth of the present invention is a continuously integrated reinforcing cloth that fits the entire cushion material having a complicated shape, and can be easily manufactured by a single molding process.

Further, since the molded product has a complicated three-dimensional curved surface shape as described above, it has a property of having a certain degree of structural rigidity against deformation and maintains the shape after molding (hereinafter, It has a shape-retaining property including the property that it does not return to the shape), and even when it is set on the inner surface of the mold, the required number of fixtures such as pins is very small.

Further, since it has an accurate shape, it fits well in the mold, and the nonwoven fabric of the present invention has a three-dimensional network structure, and when integrally molded by resin foaming, the foamed layer reaches the inside of the nonwoven fabric and exhibits sufficient adhesive strength. However, the occurrence of molding defects is greatly reduced.

Further, while having the above-mentioned shape retention property,
Since it is a continuous integral non-woven fabric, it also has appropriate flexibility that can follow the deformation of the cushion material such as resin foam.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, a back reinforcing cloth for back cushion material according to an embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is a perspective view showing an example of a back surface reinforcing cloth for a back cushion material of the present invention. For the sake of clarity, the reinforcing cloth used for the cushion material 5 shown in FIGS. 2 to 3 is taken as an example.

The reinforcing cloth 1 is made of a thermoformable non-woven fabric. As such a non-woven fabric, thermoplastic fibers such as acrylic, polyester, polypropylene, vinyl chloride and nylon are used alone or as a mixture. Further, other fibers may be mixed.

Among these non-woven fabrics, those made of acrylic fibers have the property of being accurately molded with a small force to every corner of a complicated shape, and after being molded, returning to the shape before molding. It is preferable because it has almost no thermoforming property, that is, it has both excellent thermoformability and excellent shape retention. Specific examples of such preferable acrylic fibers include Kanekalon (trademark, manufactured by Kaneka Corporation).

The above-mentioned non-woven fabric may be dry or wet, and in general, it is preferably used as a molded reinforcing fabric for cushioning material, and has a basis weight (weight per unit area) of 80 to 1000 g / m 2.
² , especially as a backside forming reinforcing cloth for back cushion material, the range is 80 to ²⁰⁰ g / m ² .

When it is less than the above range (when it is too thin, etc.), the moldability and shape retaining property of the drawn portion and the like tend to deteriorate, and when it exceeds the above range (when it is too thick, etc.). However, it is difficult for the mold to be easily fitted into the mold, and the moldability is deteriorated, and it becomes difficult to obtain a foam exactly as the mold shape when foam-molding the resin of the cushion material.

The reinforcing cloth 1 of FIG. 1 is produced by thermoforming the above-mentioned nonwoven fabric.

The mold used for thermoforming has a shape corresponding to the portion defining the back surface of the cushion material of the foam molding die for producing the cushion material.

Therefore, the back molding portion of the foam molding die may be used as it is, but in the example of FIG. 1, in order to facilitate thermoforming of the reinforcing cloth 1, the shape of the back molding portion of the foam molding die is penetrated. It is formed by using a mold having a shape in which the hole 3 is expanded into a standing shape.

That is, the molded reinforcing cloth 1 has a back portion 2
The through hole 3 and the folded-back portion 4 are formed so that the through hole 3 is substantially perpendicular to the back 2.

When thermoforming is performed with the back surface shape of the cushion material expanded, the obtained reinforcing cloth 1 does not have a shape-retaining property in the expanded portion, but the thermoforming operation is easy. In such a case, it is preferable to adopt a reinforcing cloth shape obtained by partially expanding the shape of the back surface of the cushion material.

In FIG. 1, the upper surface of the reinforcing cloth (the surface visible in the drawing) is the surface to be joined with the cushion material.

The reinforcing cloth 1 is thermoformed into the shape shown in FIG. The thermoforming conditions are not particularly limited, and for example, the nonwoven fabric is heated to about 60 to 200 ° C., particularly about 100 to 130 ° C., and then the male and female molds having the above-described predetermined shapes are sandwiched.

Unnecessary portions around the formed nonwoven fabric are cut off, and the folded-back portion 4 is folded back in the direction of arrow A in FIG.
It is attached to the foaming mold.

As described above, the reinforcing cloth 1 made of the formed non-woven fabric has an accurate shape, and has an appropriate shape-maintaining property and flexibility, so that it fits well in the foam molding die,
Easy to mount and fix.

A resin is injected and foamed into the foam molding die to which the reinforcing cloth 1 is attached, and a cushion material having a reinforcing cloth on the back surface is obtained.

The reinforcing cloth made of the formed non-woven fabric has an appropriate flexibility, sufficiently follows the deformation of the cushion material, and after being attached to the support member, the cushion material is prevented from being damaged by sliding with the support member. Protect well.

[0040]

The molded reinforcing cloth for cushioning material of the present invention has the following effects.

It is a continuous monolith and is easily manufactured by a single process.

It has an accurate shape and has good adhesion to the resin foamed cushioning material, so that it fits well in the foaming mold for cushioning material and the occurrence of molding defects is prevented.

It has a shape-retaining property. Therefore, the number of fixtures required for attachment to the foam mold is small, and the attachment work is easy.

It has appropriate flexibility and sufficiently follows the deformation of the cushion material.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a back surface reinforcing cloth for a back cushion material of the present invention.

FIG. 2 is a perspective view showing an example of a vehicle seat including a backrest using the reinforcing cloth.

FIG. 3 is a vertical cross-sectional view of the backrest shown in FIG. 2 taken at a position of a through hole portion.

[Explanation of symbols]

 1 Reinforcement cloth 2 Back part 3 Through hole part 4 Folding part 5 Cushion material 6 Additional member

Claims (2)

[Claims] 1. A molded reinforcing cloth for cushioning material, which is for reinforcing the surface of an inner member of a resin foam, wherein a non-woven fabric having moldability is molded into a shape conforming to the shape of the foam. 2. The reinforcing cloth according to claim 1, wherein the non-woven fabric is made of acrylic fiber.