JPH058333A - Rear side sheet for seat pad - Google Patents

Abstract

PURPOSE:To provide a rear side sheet which does not generate an abnormal sound at a part where the rear side sheet for a seat pad is brought into contact with a seat spring when the atmospheric temp. reaches a low temp. such as about 5 deg.C. CONSTITUTION:A rear side sheet 10 for a seat pad wherein the first layer is a polyester knitted cloth 1 prepd. by knitting a polyester fiber by means of a pile knitting machine, the second layer is a foamed urethane foam 2, the third layer is a urethane film 3 and the fourth layer is a non-woven fabric 4 and these four layers are laminated and integrally adhered together.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a back sheet of a seat pad in an automobile, which is used integrally with a seat pad by permeating a urethane material into the back sheet when molding a urethane foam.

[0002]

2. Description of the Related Art As is well known, an automobile seat pad is a flexible object placed between a seat spring and a skin material, and molded products of molded urethane foam are often used. Nonwoven fabric such as coarse wool felt is exclusively used for the back sheet of the conventional seat pad, and urethane foam penetrates into the nonwoven fabric during molding of urethane foam to bond the pad and the nonwoven fabric together. The nonwoven fabric impregnated with urethane foam forms a hard layer and serves as a spring bearing material for seat springs.

[0003]

A nonwoven fabric having a hard layer impregnated with a urethane material is excellent in strength and durability and is preferable as a spring bearing material, but urethane foam passing through the nonwoven fabric is partially scattered on the surface. The portion that rubs against the sheet spring may be non-woven fabric or urethane foam. For this reason, when the temperature of the atmosphere becomes a low temperature of about 5 ° C., a large squeaking noise such as a squeaky noise is generated at the portion where the seat spring and the nonwoven fabric come into contact with each other.

It is an important issue that the seat of an automobile holds the body of the driver and the occupant, absorbs vibrations from the road surface, minimizes fatigue, and is comfortable to ride. Recently, passenger cars have become more sophisticated, the engine noise has been reduced, and the quietness and airtightness of the passenger compartment have been significantly improved. However, if a loud noise suddenly occurs from the seat, not only is the riding comfort uncomfortable, but the driver may be surprised and mistakenly steer the steering wheel, which may lead to a traffic accident, which is a safety issue.

A silencer pad is used in a portion where the seat springs interfere with each other to generate an abnormal noise. However, the silencer pad cannot be adopted because of its problems in strength and durability. We tried to improve the shape and structure of the seat spring and the non-woven fabric, but could not eliminate the large noise generated when the temperature dropped.

[0006]

SUMMARY OF THE INVENTION The present invention provides a backside sheet in which no abnormal noise is generated at a portion where a backside sheet of a seat pad and a seat spring are in contact with each other no matter how the atmospheric temperature decreases by 5 ° C. or less. The first layer is made of synthetic fiber made of polar polymer, the second layer is made of synthetic resin, the second layer is made of soft resin foam or resin cotton, and the third layer is made of urethane material. It is characterized in that the barrier layer for preventing permeation and the fourth layer are formed by laminating four layers of a nonwoven fabric layer which can be impregnated with a urethane material and are integrally bonded.

[0007]

The back sheet integrated by laminating four layers as described above is punched and cut into a predetermined seat pad shape, put into a mold, and molded into a urethane foam in a known manner. Due to the barrier layer in the layer, the urethane material is impregnated only in the fourth layer and becomes integral with the seat pad.

Since the urethane material does not penetrate into the cushion layer of the second layer and the spring receiving layer of the first layer, neither is a hard layer. The sponge-like first layer and the second layer are flexible, and since the surface contacting the seat spring (the surface of the first layer) is soft, no abnormal noise is generated even when the spring is rubbed. Since the first spring receiving layer is a layer having excellent strength and durability, it does not wear even if it comes into contact with the cushion spring for a long period of time and rubs against it.

[0009]

EXAMPLE Referring to FIG. 1, the back sheet 10 of the first example.
The first layer 1 is a 200 g / m ² polyester knitted fabric knitted by pile knitting (for example, what is commonly referred to by those skilled in the art as French pile), and the second layer 2 is 0.022 kg / m ³ foamed urethane foam. The third layer 3 is a urethane film having a thickness of 30 μm, and the fourth layer 4 is a non-woven fabric having a weight of 150 g / m ² , and these four layers are integrally bonded by laminating to have a thickness of about 6 mm. ing.

In consideration of quality and economy, the polyester knitted fabric 1 of the first layer is 150 to 250 g / m ² , and the foamed urethane foam 2 of the second layer is 0.01 to 0.05 kg / m ² .
m ³ , the third layer urethane film 3 has a thickness of 10 to 60 μm, and the fourth layer nonwoven fabric 4 has a thickness of 100 to 400 g / m ^2.
Those which are practically preferable.

The laminating process is performed by a known laminating machine or bonding machine, and an outline of the manufacturing will be described with reference to FIGS. 2 and 3.

Materials 1A to 4 for each of the first to fourth layers 4
As shown in FIG. 4, A is wound around the paper tube 6 in the same width m by a predetermined length like a roll.

The laminating machine 8 shown in FIG.
2, the upper and lower rollers 11, 13 are pressed against each other by springs, etc., and the three rollers 11, 12, 13 having substantially the same diameter rotate at a high peripheral speed of about 40 m / min in the direction of the arrow in FIG. There is. The surface of the second layer of urethane foam 2 wound around the upper roller 11 and fed, is melted by the flame of the gas burner 14 and guided by the guide roller 15 to guide the middle roller 12
The polyester knitted fabric 1 of the first layer and the urethane foam 2 of the second layer melted by the flame, which are wound and fed to the upper layer, are polymerized and sandwiched between the upper and middle rollers 11 and 12 and the first layer and the second layer. Two layers of two cloths are fused together.

The back surface on the side of the urethane foam 2 where the polyester knitted fabric 1 and the urethane foam 2 are fused is melted by the flame of the gas burner 16 and polymerized with the urethane film 3 of the third layer between the middle and lower rollers 12 and 13. It is pinched and the two cloths of the second layer and the third layer are fused.

The laminated sheet 5 in which the front and back surfaces of the second layer urethane foam is melted and the first layer and the third layer are integrally adhered is wound around the paper tube via the guide roller 17 and laminated. It becomes the sheet roll 5A.

The laminated sheet 5 to which the three layers are bonded and the non-woven fabric 4 as the fourth layer are bonded together by a bonding machine 9 shown in FIG. 3, for example.

The bonding machine 9 of FIG. 3 is a roll-type bonding machine called a roll coater, and the nonwoven fabric 4 pulled out from the nonwoven fabric roll 4A is guided by guide rollers 21 and rotated in opposite directions. It is guided between the gluing roller 22 and the pressing roller 23. Adhesive liquid 2 in container 24
The non-woven fabric 4 is sandwiched and fed by the sizing roller 22 and the pressing roller 23 that are immersed in the 5 and rotating, and the adhesive liquid 25 is applied to the back surface of the non-woven fabric 4. Non-woven fabric 4 with adhesive liquid applied
The laminated sheet 5 is sandwiched and fed by the pair of sandwiching rollers 29, 29 and bonded to form the backside sheet 10. The adhered backside sheet 10 is sandwiched between a high-temperature drying roller 26 and an endless belt 28 that rotates so as to come into contact with the drying roller 26 by the rotation of a driving roller 27, is fed, is dried, and then is dried. The back side sheet roll 10A in which the back side sheet 10 is wound around the tube is formed.

The bonding machine 9 may be a known bonding machine such as a spray-type bonding machine which sprays the bonding surface of the cloth in a spray form.

In the above embodiment, the urethane film 3 is used as the third barrier layer, but the surface of the fourth layer non-woven fabric 4 (the surface of the second layer bonded to the foamed urethane foam) is about 10 to 10. A urethane coating having a thickness of 50 μm may be applied, and the urethane coating layer may be used as the third barrier layer. In this case, the back sheet 10 can be obtained by simply adhering the urethane-coated non-woven fabric, the foamed urethane foam (second layer) and the polyester knitted fabric (first layer) together by the laminating machine 8.

In still another embodiment, the first layer is 100-
300 g / m ² polyester woven fabric, second layer 30-1
The urethane cotton 3 and the non-woven fabric 4 of the first embodiment may be used as the resin cotton of 00 g / m ² and the third and fourth layers. Second
When resin cotton is used for the layer, it cannot be bonded by the fusion method (the laminating machine 8 cannot be used), 2
The layers must be glued together.

As is apparent from the above description, the present invention has the first layer as a synthetic fiber layer having strength and durability, the second layer as a layer having a soft cushioning property, and the third layer as a permeation of urethane material. The purpose is not limited to the above examples, as long as the fourth layer for preventing the above is a laminate of four nonwoven fabric layers that can be impregnated with a urethane material.

[0022]

EFFECT OF THE INVENTION In the back sheet of the present invention, when the seat pad is molded with urethane foam, the barrier layer prevents penetration of the urethane material, the cushion layer and the spring receiving layer are flexible, and the spring receiving layer is the seat spring. Since it is in soft contact with the seat, no abnormal noise is generated from the seat while the vehicle is operating even when the temperature of the atmosphere is low. Therefore, neither the driver nor the occupant will be surprised by a loud noise that suddenly occurs during driving, and the driver can comfortably drive safely.

When the back sheet of the present invention is manufactured by using the cushion layer of the soft resin foam, the front surface and the back surface are melted by the flame and the three layers can be welded at a high production rate, so that the productivity is improved and the cost is reduced. The back sheet is obtained and economical.

[Brief description of drawings]

FIG. 1 is a perspective view of a back side sheet showing an embodiment of the present invention.

FIG. 2 is an explanatory diagram for manufacturing a backside sheet with a laminating machine.

FIG. 3 is an explanatory diagram of a roll-type bonding machine.

FIG. 4 is a perspective view of a polyester knitted fabric roll.

[Explanation of symbols]

1st layer 2 Second layer 3rd layer 4th layer 8 laminating machine 9 bonding machine 10 Back sheet

Continuation of front page (51) Int.Cl. ⁵ Identification number Office reference number FI Technical display location D04H 1/42 U 7199-3B T 7199-3B 1/54 Q 7199-3B D06M 17/10

Claims (2)

[Claims] 1. A first layer is a spring bearing layer made of synthetic fibers made of polar polymer, a second layer is a cushion layer made of soft resin foam or resin cotton, and a third layer is a barrier for preventing penetration of urethane material. A back sheet of a seat pad, wherein the fourth layer and the fourth layer are laminated and integrally bonded by laminating four layers of a non-woven fabric layer which can be impregnated with a urethane material. 2. A polyester knitted fabric made by knitting polyester fibers with a pile knitting machine as a first layer, urethane foam as a second layer, urethane film as a third layer, and nonwoven fabric as a fourth layer.
The back sheet of a seat pad of claim 1, wherein the layers are laminated and adhered together.