JPH05337258A - Seat for vehicle - Google Patents

Abstract

PURPOSE:To execute recycling, to decrease stuffiness, and to improve heat settling resistance by forming a cushion layer by polyester fibers, placing heat adhesive property nonwoven cloth whose adhesive component is polyester elastomer between side cloth and the cushion layer and unifying them. CONSTITUTION:Cushion layers 3, 4 and 5 of a seat for a vehicle are formed by polyester fibers, and between side cloth 1 and the cushion layers 3, 4 and 5, heat adhesive property nonwoven cloth 2 whose adhesive component is polyester elastomer is placed and they are unified. Also, at least one layer of the cushion layers 3, 4 and 5 is formed by a structure in which solid crimped polyester fibers and heat adhesive fibers consisting of polyester elastomer are subjected to thermal forming. This seat is small in a stuffy sense and has elasticity, is satisfactory in a sitting sensation and excellent in settling resistance, and scarcely generates creases. Moreover, the cushion body, inclusive of side cloth can be recycled, therefore, even if it is used in large quantities, environmental pollution is not generated, and resources saving and unitlization resources can be promoted.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle seat that is recyclable, has less stuffiness, and has improved wrinkles and fatigue.

[0002]

2. Description of the Related Art As a vehicle seat, polyurethane is often used as a cushion layer, and its side is lined with latex or the like. This seat has excellent flattening resistance and cushioning properties, is inexpensive, but has poor breathability, so it tends to get damp and lacks comfort. In addition, when discarding, toxic gas is generated when incinerated, and it is necessary to dispose of it while removing it, and the cost increases because corrosion of the incinerator also progresses. Since it remains on the ground as it is, it is difficult to reclaim it.
In recent years, it seems that studies of collecting, disassembling, and recycling have also started, but the fact is that recycling is rarely performed due to the huge amount of use.

In recent years, in order to reduce stuffiness, a vehicle cushion material using fibers has been proposed. For example, natural fibers and adhesives (Japanese Patent Laid-Open No. 52-101164, etc.), synthetic fibers and adhesives using urethane (Shokai Sho 62-
59500, etc.) and those using latexes (Japanese Patent Laid-Open No. 60-48781, etc.), but since they are composed of heterogeneous compositions, they have the same problems as polyurethane.

Further, although a cushioning material using a polyester fiber having a low melting point polyester fiber as an adhesive component is known, it is difficult to use it for a vehicle seat which is used under severe conditions because it is easily worn. Also, there is no concrete proposal considering recycling.

[0005]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems of the prior art, is recyclable, has less stuffiness, is comfortable to sit on, and has elasticity, settling resistance and lateral wrinkles. The purpose is to provide a vehicle seat with improved generation.

[0006]

[Means for Solving the Problems] A means for solving the above problems, that is, the present invention is a vehicle seat comprising a side layer and a cushion layer, the cushion layer comprising a polyester fiber, and the side layer and the cushion layer. At least one of the vehicle seat and the cushion layer is characterized in that a heat-adhesive non-woven fabric having a polyester elastomer as an adhesive component is arranged between the two and The above vehicle seat comprises a thermoformed structure such as an adhesive fiber.

In the seat of the present invention, the side material, the non-woven fabric, and the cushion layer are made of polyester fiber to enable recycling. Therefore, even when discarding, if only the metal part is removed, it can be repelletized or decomposed into the monomer and recovered. Also, transport problems are alleviated by hot pressing. It is not preferable to include a different component because such a measure cannot be taken.

In the seat of the present invention, a thermal adhesive non-woven fabric containing polyester elastomer as an adhesive component is disposed between the side fabric made of polyester fiber and the cushion layer to be integrated. Since the heat-bonded nonwoven fabric heat-bonds the side material and the polyester elastomer, it acts as a stretchable backing and suppresses the generation of wrinkles. It also functions as a wading layer having good breathability and elasticity.

When the polyester elastomer is not used, the stretchability is inferior, so that the generation of wrinkles cannot be suppressed due to plastic deformation. In addition, since it is integrated with a cushioning layer made of polyester fiber with good air permeability, it deforms together with the cushioning layer and adheres well to the kidneys, thighs, waist, etc. Can be generated and stuffiness can be reduced.

In the case of polyurethane, since it is a foam having many closed cells, the air permeability is poor, and those using polyurethane for the wading layer and the cushion layer tend to get stuffy. Furthermore,
Polyester fiber does not heat steam, so it is easy to release heat through ventilation, and relatively good thermal conductivity makes it easy to maintain a comfortable temperature. Polyurethane makes it easy to maintain a comfortable temperature, but polyurethane makes it comfortable. It has a drawback that it is difficult to keep the temperature. In addition, the polyester elastomer is
Since the rubber elastic component improves the vibration absorption, it becomes possible to provide a riding comfort with improved comfort.

The polyester used in the present invention means polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PE).
N), polycyclohexylene dimethyl terephthalate (PCHDT), polyethylene isophthalate (PE
I) and the like and their copolyesters such as block copolymers of PBT and polytetramethylene glycol (PTMG) and copolymers of PET and PEI, whose main repeating units are composed of polyester. The polyester elastomer is a block copolymer of a hard segment and a soft segment. Examples of the hard segment include PET, PEN, PBT, PCHDT, and the like, and examples of the soft segment include PTMG and polohexamethylene glycol (PHMG). , Polypropylene glycol (PPG), polycaprolactam (PCL)
Can be exemplified.

A particularly preferred combination is PBT-PT.
MG, PEN-PTMG, PBT-PCL, etc. can be illustrated. The melting point (Tm) is 150 because it adds heat resistance.
The temperature is preferably 220 ° C. or lower, which allows contact formation at a processing temperature at which the heat resistance of the base material and the heat resistance of the core component can be maintained.
The preferred composition of the matrix fiber is PET, PE
Examples thereof include N, PCHDT, PBT, and their copolymers and / or blends. The polyester fiber of the present invention may contain various additives, modifiers, and colorants as necessary to achieve the above composition, and may be dyed, but 95% or more may be heated. It is a fiber composed of a plastic polyester component and includes a multi-component composite fiber. The heat-bonding fiber is preferably a composite fiber such as sheath core because it retains its shape, and PB is used as the core component.
T, PET and the like are preferable. The heat-bonded non-woven fabric may be 100% heat-bonded fibers or may be a mixture of polyester fibers.

At least one cushion layer of the seat of the present invention is composed of a cushion layer heat-bonded with a polyester elastomer having a three-dimensional crimped polyester fiber as a base material, whereby the settling resistance and elasticity are improved. Therefore, it is preferable. The non-elastomer heat-bonded fiber has improved hardness, but has poor stretchability and poor settling durability. It is preferable to use a three-dimensional crimped polyester fiber as a base material because it is bulky and can impart elasticity.

FIG. 1 is a view showing a sectional structure of a seat of the present invention. The cushion layer (A) which is in contact with the wading layer is a soft and bulky cushion layer, and the touch layer has a soft touch and a large amount of deformation to improve ventilation. Can be added. The second layer (B) has the function of a cushion body. It has elasticity, and is deformed under a low load, and is less likely to be deformed under a high load, so that it is possible to impart the effect of promoting ventilation due to the deformation and maintaining the body shape and reducing the feeling of depression. The hardness of the third layer (C) is in contact with the spring layer or the frame of the seat so as to support the form of the seat.
It is desirable that the pressure is 50 kg or more when compressed at least 50%. The adhesive component constituting the cushion layer is preferably
By using a polyester elastomer, the above effects can be enhanced.

The matrix of the layer (A) has a yarn-yarn static friction coefficient (μs) of at least 0.25 or less, more preferably,
By setting the ratio to 0.2 or less, the crimp recoverability can be improved. The crimp is preferably a three-dimensional crimp. The layer B is preferably three-dimensional crimped. The base material of the layer (C) may be three-dimensionally crimped or mechanically crimped, or may be a mixture of both fibers, but in order to reduce the weight and to prevent deformation, it is preferable to mix the fibers.

The denier of the base material of each layer is 3 to 1 for the A layer.
0 denier is preferred because of its softness, and layer B is preferably 6 denier to 20 denier because it easily adds a cushioning function. The C layer preferably has a denier of 8 to 100 denier because it imparts hardness. The bulk height of each layer is 0.03g for layer A
/ Cc or less, the B layer is preferably 0.01 to 0.06 g / cc, and the C layer is preferably 0.04 to 0.10 g / cc. The cross-sectional shape is preferably a hollow cross-section, more preferably a modified cross-section or a modified hollow cross-section because it can impart more bending rigidity. The preferable content of the heat-bonding fiber is 5 to 30% in the A layer and 20 to 5 in the B layer.
0%, C layer 20 to 100%.

An example of the method of manufacturing the seat of the present invention will be described in detail below. The polyester elastomer is prepared by a known method, for example, by charging dimethyl terephthalate, tetramethylene glycol and PTMG together with a small amount of a catalyst and an antioxidant, and subjecting the resulting mixture to transesterification and polycondensation to obtain a PBT-PTMG block copolymer. Then, for example, using PBT obtained by a conventional method as a core component, a known composite spinning machine at 265 ° C.
To obtain sheath core fiber. When the Tm of the polyester elastomer is 180 ° C. or less, water cooling can prevent fusion. The unstretched yarn thus obtained is stretched at a temperature at which it is not fused, mechanically crimped and then cut to obtain a heat-bonded fiber. The base material is obtained by a known method. For example, PET is subjected to asymmetric cooling using a hollow or irregularly shaped neutral nozzle, or unstretched yarn with latent crimping ability is obtained by composite spinning and stretched, and then three-dimensional crimping is caused to occur or the three-dimensional crimping is performed after cutting. It is obtained by expressing. A preferred stretching is a high-strength, high-strength stretching, which gives high modulus retention. It is possible to reduce the friction coefficient by attaching a slippery oil agent during stretching.

The heat-bonded fiber thus obtained and the base material are pre-opened by a conventional method, for example, at a mixing ratio of 30/70, opened with a card, and laminated to obtain a web having a desired basis weight. Air ray can be used for opening. Then, continuously or if necessary, it is preferably crimped to 2/3 to 3/4 of the desired bulk and heat-bonded so that the bulkiness becomes a little higher than the desired bulk, and a molded product of each layer is obtained. The heat fusion temperature is preferably 10 ° C. or higher and 30 ° C. or lower than the Tm of the heat adhesive component. The heat-bonded nonwoven fabric can also be obtained by melt-blowing a polyester elastomer or by a spunbond method. Further, it can be obtained by subjecting the above-mentioned card web to a multi-step treatment with a needle punch, a water punch, or the like.

Then, the side material and the heat-bonded non-woven fabric obtained by the known method are heat-sealed and bonded by the known method. Prior to heat fusion, entanglement temporary joining may be performed with a needle punch or the like. When the melting point of the heat-adhesive component is high, it is preferable to preheat the heat-adhesive non-woven fabric to cool the side material side, and press-bond with the side material material for rapid cooling.

The cushion layer is preferably gold formed. First, the formed layer A, layer B and layer C are placed on a preheated female die and press-formed with a male die. The pressing temperature is preferably 5 ° C. higher than the melting point of the heat-adhesive component. The pressing pressure is preferably 10 kg or more. As for heating, it is preferable to heat the inside of the mold by passing hot air or superheated steam. Processing time is 30
It is preferably not less than 2 seconds and not more than 1 minute. Then cool and remove the molded cushion from the mold, preferably 100
Anneal at 10 ° C to 130 ° C for 10 minutes or more. Alternatively, it is annealed in the mold. This is preferable when a polyester elastomer is used as the heat-adhesive component because the heat-resistant and sag resistance is significantly improved. When molding with a laminated web instead of a molded body, when each layer web is placed in a female mold and similarly molded with a male mold, the heating temperature is
The melting point is preferably + 10 ° C. to + 20 ° C., and the treatment time is preferably 3 minutes or more. Next, the molded cushion layer is placed and fixed on the seat frame, and the heat-bonded non-woven fabric is bonded to the side fabric to obtain the seat of the present invention.

The seat thus obtained is recyclable, has less stuffiness, is comfortable to sit on, and has excellent elasticity, settling resistance, and wrinkles on the side, and is the most suitable seat for a vehicle. Also, because it is possible to make it lighter than urethane, it also saves energy for both cars and trains. Since the integral molding process by heat bonding can be mass-produced, it can be provided at low cost in terms of cost.

[0022]

The present invention will be described in detail with reference to the following examples.

Examples and Comparative Examples

Preparation of Thermal Adhesive Component 645 parts of dimethyl terephthalate (DMT) and 449 parts of 1.4 butanediol (1.4BD) and a molecular weight of 200.
0 polytetramethylene glycol (PTMG) 132
8 parts were charged with a small amount of a catalyst and an antioxidant and polycondensed to produce a polyester elastomer. The produced polyester elastomer was pelletized and vacuum dried at 40 ° C. for 48 hours to obtain a heat-adhesive component. The melting point of the obtained polymer was 189 ° C. A non-elastomeric polyester was made for comparison. 776 parts of dimethyl terephthalate, 776 parts of dimethyl isophthalate and 496 parts of dimethylene glycol were charged with a small amount of a catalyst and polycondensed to produce a polyester polymer. The melting point of the obtained non-elastomeric polyester was 110 ° C.

Preparation of Thermally Bonded Fiber The polyester elastomer and non-elastomeric polyester prepared by the above method were used as sheath components, respectively. The sheath component was melted at 220 ° C. and the single hole discharge rate was 3 g / min, and the core component was PBT melted at 260 ° C. and the single hole discharge rate was 3 g / min. The spinning temperature was 265 ° C., and spinning was performed using a 4-hole composite spinning nozzle. An undrawn yarn was obtained at a take-up speed of 700 m / min.
The unstretched yarn obtained was cut and stretched in a hot bath at 60 ° C (MD
R) was drawn at a rate 0.8 times that of R), then combined with 20,000 denier, crimped, cut, and set at low temperature. The characteristics of the obtained adhesive fiber are shown in Table 1.

[0026]

[Table 1]

Preparation of Base Material Fiber PET having an intrinsic viscosity of 0.63 was spun at 285 ° C. from a YU type nozzle at a discharge rate of 2 g / min and 6 g / min per single hole, and 2 m / sec from a position 30 mm directly below the nozzle. The unstretched yarn that was rapidly cooled with the cooling air of
0.7 times DR, 0.85 MDR at 2nd 160 ° C
The drawn yarn obtained by cooling the MDR 0.95 times at the third stage at 220 ° C. and the fourth stage at a constant length is cut into 64 mm, opened, and then crimped at 160 ° C. and then developed. Compress a little 2
The base material was obtained by re-heat treatment under the temperature condition of 00 ° C. For the discharge amount of 2 g / min, a slippery finishing oil agent and an ordinary finishing oil agent were applied during stretching. Table 2 shows the characteristics of the obtained base material fibers.

[0028]

[Table 2]

Preparation of heat-adhesive non-woven fabric The obtained heat-adhesive fibers (1-1, 1-2) and base material fibers (2
-2) was mixed at a ratio of 50/50, a web having a basis weight of 80 g / m ² was prepared with a card, heat-treated with a far-infrared heater, water-punched at a pressure of 20 Kg / cm ² , and dried. A heat-adhesive non-woven fabric was prepared.

Joining with side fabric Using a moquette having a basis weight of 300 g / m ^{2 made} of polyester fiber as the side fabric, the heat-bonded nonwoven fabric is preheated with hot air of 130 ° C. and 190 ° C. and supplied to a press roller heated to 200 ° C. Then, the side material was directly supplied to the press roller to obtain a press melting point joined body of the side material and the heat-bonded nonwoven fabric. Table 3 shows the bonding conditions of each sample and the air permeability of the obtained bonded body.

[0031]

[Table 3]

Preparation of cushion body The obtained heat-bonding fiber and the base material fiber were respectively set to 10/90,
After premixing with an opener at a mixing ratio of 30/70,
Open with a card and have a basis weight of 200 g / m ² (A), 150
Webs of 0 g / m ² (B) and 1000 g / m ² (C) are prepared, and the webs of (A), (B), and (C) are laminated, and the temperature is 10 to 20 ° C. higher than the melting point of the heat-bonding fiber. Heat bonding was performed at a temperature to prepare a hard wire body (cushion body). Then, the obtained hard cotton body was placed on a preheated female mold to form A layer, B layer, and C layer.
Layers are laminated in order, pressed with a male die at a pressing pressure of 10 Kg, and hot air heated above the melting point or heated is passed (while sucking) for 50 seconds, then 100 ° C, 130 ° C.
Then, they were annealed to obtain cushions for the seat and back. The deep-drawn portion was molded twice. Table 4 shows the conditions for forming the cushion body.

[0033]

[Table 4] The obtained cushion was attached to the seat frame, and the fusion bonded body of the side fabric-heat-bonded nonwoven fabric prepared in (3-1) and (3-2) was attached to each cushion body, for a total of four types (comparative example). (Including also) seats were created and performance was evaluated. The performance is evaluated by the following method. That is, six panelists are selected, a seat is attached to a driving stone of a commuter car, and 1
The seats were replaced every week and a wearing test was conducted for 6 months. The evaluation was made by ○, ×, and △, and each evaluation item and the evaluation standard were as follows. Feeling of stuffiness: O was good, Δ was normal, and X was bad. Elasticity: ○ was good, Δ was normal, and × was bad. Comfortable to sit: ◯ was good, Δ was normal, and × was poor. The stuffiness, elasticity, and sitting comfort were evaluated twice at the start of the test and immediately before the final replacement. Wrinkles: ○ is not a concern, △ is a concern, and × is an intolerance. The heat settling property is evaluated by a holding ratio of the thickness after repeatedly dropping a load of 50 kg at 1 HZ and 20,000 times in a 70 ° C. atmosphere. The retention rate, x, was less than 30%, but was evaluated at 3 levels. The results obtained are shown in Table 5.

[0034]

[Table 5]

As shown in Table 5, the seat of the present invention was less stuffy, had a comfortable sitting feeling, had good settling resistance, and had few wrinkles. Those that deviate from the present invention are remarkably stuffy when cushion urethane is used, and the comfort of sitting is normal (standard). Those that did not use an elastomer as an adhesive component between the lateral surface and the cushion had wrinkles significantly and had poor durability.

[0036]

EFFECTS OF THE INVENTION The seat according to the present invention has less damp sensation, elasticity, good seating comfort, excellent settling resistance, and less wrinkling. Furthermore, since the cushion body including the side land can be discarded or recycled, it does not cause pollution even when used in large quantities, and it is possible to provide a seat that can promote resource saving and resource utilization.

[Brief description of drawings]

FIG. 1 is a view showing a cross section of a seat of the present invention.

FIG. 2 is a view showing a molding form of a cushion body of the seat of the present invention.

FIG. 3 is a perspective view showing an example of a seat of the present invention.

[Explanation of symbols]

1 is a side ground, 2 is a heat-bonded nonwoven fabric, 3 is a cushion layer A, 4
Is a cushion layer B, 5 is a cushion layer C, 6 is a spring layer, 7 is a female mold, 8 is a male mold, 9 is a hot air or steam vent, 10 is a headless part, 11 is a back part, 12 is a seat part Indicates.

Claims (2)

[Claims] 1. A vehicle seat comprising a side layer and a cushion layer, the cushion layer comprising a polyester fiber,
A vehicle seat characterized in that a heat-adhesive non-woven fabric having a polyester elastomer as an adhesive component is disposed and integrated between the lateral side and the cushion layer. 2. The vehicle seat according to claim 1, wherein at least one of the cushion layers has a structure in which three-dimensional crimped polyester fibers and thermo-bonding fibers made of polyester elastomer are thermoformed.