JPH06125825A - Sheet cover and its production - Google Patents

Abstract

PURPOSE:To easily and surely mount the sheet cover to a cushion material along its surface shape by molding the sheet cover to a shape coinciding with the shape of the cushion material without requiring special fabricating conditions, etc. CONSTITUTION:The sheet cover is obtd. by using a cover material 34 having a front surface material 31, a backing material 32 contg. 10 to 100wt.% thermoplastic fibers having thermal fusibility and an elastic material 33 interposed between these materials at need and molding this cover material to the shape coinciding with the surface shape of the cushion material 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is applied to the production of seat cushions and seat backs for automobiles and office chairs.
The present invention relates to a seat cover attached to the surface of a cushion material forming the seat cushion or the seat back and a manufacturing method thereof.

[0002]

2. Description of the Related Art Generally, seat cushions and seat backs for automobiles, office chairs, etc. have a skin material, a backing material, and an elastic material interposed between these materials on the surface of a cushion material made of urethane foam or the like. It is configured by attaching a seat cover consisting of. In addition, recently, in order to enhance the design appearance of the chair and give a high-class feeling, the cushion material is formed into a complicated three-dimensional curved surface shape, or a groove or the like is formed in the cushion material, and these three-dimensional curved surface shape portions or grooves are formed. By covering the entire surface of the cushion material with the seat cover in line with the above, the seat cushion and the seat back are given a feeling of unevenness or a three-dimensional effect.

However, when the seat cover is attached to the cushion material having the groove or the like, conventionally, a seat cover previously sewn into substantially the same shape as the cushion material is used, and the seat cover is attached to the cushion material. Covering the surface, the portion corresponding to the three-dimensional curved surface shape portion and groove provided on the cushion material of the seat cover is fixed to the cushion material side by hog ring or adhesive means, and the end portion of the seat cover is fixed to the cushion material. By fixing to the fixing member side, the entire seat cover is covered along the entire surface of the cushion material.

[0004]

However, since the conventional seat cover as described above is fixed to the cushion material by a hog ring, an adhesive means or the like, a large number of fixing tools are required. A great deal of time and effort is required for fixing with these fixing tools. Moreover, when the seat cover is fixed to the cushion material side using a large number of fixing tools, the cushion material is deformed and the appearance of the seat cushion or seat back is changed, and it is difficult to obtain stable quality. There was also a problem such as.

Conventionally, in order to solve the above-mentioned various problems, a seat cover having a special thermoformable urethane resin interposed between a skin material and a backing material is used. It has been proposed that the cushion material be molded into a shape that matches the cushion material so that the cushion material can be attached following the surface shape of the cushion material. However, since this means uses a special urethane resin, special processing conditions such as foaming and thermoforming of this urethane resin are required, which requires skill in processing and the productization rate deteriorates. However, it is generally difficult to adopt because it causes other problems.

The present invention has been made in view of the above problems, and an object of the present invention is that it can be formed into a shape that matches a cushion material without requiring special processing conditions, and the cushion material can be formed. To provide a seat cover that can be easily and surely attached according to the surface shape of the vehicle and a manufacturing method thereof.

[0007]

In order to achieve the above object, the seat cover of the present invention has a two-layer or three-layer structure in which a skin material and a backing material and, optionally, an elastic material are interposed therebetween. The backing material is made of a cover material, and the backing material contains 10 to 100% by weight of thermoplastic fibers having a heat-fusible property, and is molded into a shape that matches the surface shape of the cushion material.

Further, in the method of manufacturing a seat cover according to the present invention, a backing material containing 10 to 100% by weight of thermoplastic fibers having a heat-fusible property is bonded to the back surface of the skin material, or a backing material is used. The backing material and the elastic material interposed between them are joined together to form a cover material, and the cover material is heated to a melting point of the backing material or higher to obtain the surface shape of the cushion material. It is characterized by being molded into a shape that conforms to.

[0009]

According to the seat cover of the present invention, since the backing material, which is a constituent material of the seat cover, contains 10 to 100% by weight of the thermoplastic fiber, the seat cover has a shape matching the surface shape of the cushion material. It can be molded.
Further, since the thermoplastic fiber has a heat melting property, it is fused and integrated with the remaining fiber forming the backing material and the skin material or the elastic material. Since the above-mentioned seat cover can be mold-formed by including thermoplastic fibers having a heat-fusible property in the backing material that is a constituent material of the seat cover, as in the case of molding using a conventional special urethane resin, There is no need for special foaming or thermoforming conditions, and it is possible to mold using a mold that is commonly used, without requiring special skill in processing and reducing the productization rate. The shape can be easily formed into a shape that matches the surface shape of the cushion material. The skin material or elastic material and the backing material can be fused and joined by a thermoplastic fiber having a heat fusion property, but may be adhered by various adhesives.

Further, the seat cover molded as described above can be attached so as to follow the surface shape of the cushion material without fail, and to obtain an original design appearance when used as a seat cushion or a seat back. In addition, the seat cover can be molded into an arbitrary shape that matches the surface shape of the cushion material, and can reliably follow the surface shape of the cushion material, so it is compatible with the design when manufacturing the seat cushion or the like. The range can be greatly expanded.

Further, the seat cover does not require a large number of fixing tools or the like to follow the surface shape of the cushion material, and the fixing of these fixing tools does not require a great deal of labor. It is possible to greatly simplify the work of attaching the to the cushion material side. In addition, since the seat cover is formed in a shape that matches the surface shape of the cushion material, an unreasonable fixing force is not applied when fixing it to the cushion material. There is no fear of changing the appearance of the product, and stable quality can be obtained.

Further, according to the manufacturing method of the present invention, 10 to 100% by weight of the thermoplastic fiber having a heat fusion property with the skin material.
A cover material having a two-layer structure composed of a backing material containing, or a three-layer structure composed of a skin material, the backing material and an elastic material interposed therebetween is used, and the cover material is used as the backing material. By heating above the melting point to mold and mold, a seat cover having a shape matching the surface shape of the cushion material can be easily obtained. By mounting the seat cover manufactured in this manner on the surface of the cushion material, the same operation and effect as those in the case described above can be exhibited.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows an automobile seat cushion 1 as an application example of a seat cover according to the present invention. The seat cushion 1 includes a cushion material 2 made of urethane foam or the like having a plurality of grooves 21 on an outer surface thereof, and The seat cover 3 is covered along the surface shape of the cushion material 2.

As shown in FIG. 2 (A), the seat cover 3 has a two-layer structure in which a backing material 32 is joined and integrated to the back surface of a skin material 31, or as shown in FIG. 2 (B). , A cover material 34 having a three-layer structure including a skin material 31, a backing material 32, and an elastic material 33 interposed between these materials 31, 32. As the surface material 31, for example, textiles or synthetic leather is used. In addition, the backing material 32 contains 10 to 100% by weight of thermoplastic fibers having a heat fusion property.
The skin material 31 and the skin material 31 are joined and integrated by a method such as adhesion with an adhesive or a heat fusion method. For the adhesion with an adhesive, various evaporative adhesives such as polyurethane and reactive adhesives are used. To apply the adhesive,
A spray method, a roll coater method, a brush coating method, or a dot adhesion method in which an adhesive is dispersed and applied in a small range is used. In addition, an adhesive film method may be used in which a thermosensitive adhesive such as a thermoplastic resin film or a sponge-like thin film is sandwiched and heat-pressed.

As shown in FIG. 2B, a skin material 31 and a backing material 3
When the elastic material 33 is interposed between the backing material 3 and
2 is joined and integrated with the elastic member 33 by a heat welding means such as needle punching or frame laminating,
The above-mentioned skin material 31 is joined and integrated with the elastic material 33 by a heat welding means or an adhesive material to form a cover material 34 having a three-layer structure. As the elastic material 33, for example, a thin elastic foam material (about 1 to 10 mm thick) such as urethane slab is used.

As the backing material 32, a textile or the like can be used, and also a pile cloth or a non-woven fabric sheet having a large number of loops 32a serving as a female engaging portion of a surface fastener can be used. In FIG. 2, when the seat cover 3 is attached to the surface of the cushion material 2, the seat cover 3 is simply attached to each groove 21 of the cushion material 2, and the backing material 32 is used as a backing material 32. An example using a non-woven sheet having a large number of loops 32a is shown, and details will be described later.

As a method of incorporating the thermoplastic fiber having a heat fusion property into the backing material 32, for example, FIG.
As shown in, the core is regular polyester 32b
In addition, the outer periphery of the composite fiber 32d having a core-sheath structure formed of the low melting point modified polyester 32c, or, as shown in FIG. 3B, half of the cross section is regular polyester 32b and the other half of the cross section is Side-structured composite fiber 32 formed of low melting point modified polyester 32c
d can be used. These composite fibers 32d having a core-sheath structure or a side-side structure are arbitrarily selected according to molding conditions and the like, and are mixed into a base material made of a regular polyester nonwoven fabric or a woven fabric, or only the above-mentioned composite fibers 32d. The backing material 32 is made of a non-woven fabric or woven fabric.

Further, the blending ratio of the regular polyester 32b and the low melting point modified polyester 32c forming the conjugate fiber 32d can be arbitrarily selected. The blending ratio of both of them or the conjugate fiber 32d and the base material. By changing the compounding ratio, the hardness and elasticity of the backing material 32 can be arbitrarily changed, and the cover material 34 can follow the surface shape of the cushion material 2 and is elastic and soft to the touch. can do. For example, when the surface shape of the cushion material 2 is complicated, the elasticity is increased by reducing the compounding ratio of the low melting point modified polyester 32c. Further, the mixing ratio of the modified polyester fiber 32c to the backing material 32 and the thickness of the backing material 32 are arbitrarily selected, and in addition, when the elastic material 33 made of the urethane slab is interposed, elasticity is obtained. By optionally selecting the thickness of the material 33, the cover material 34,
That is, the weight, thickness and elasticity of the seat cover 3 can be freely adjusted.

Further, the melting point of the regular polyester constituting a part of the composite fiber 32d and the base material is about 25.
In contrast to 5 to 260 ° C., the low melting point modified polyester has a melting point of 80 to 200 ° C., for example, and is arbitrarily selected according to molding conditions.

Further, the backing material 3 of the thermoplastic fiber having a heat fusion property, that is, the modified polyester fiber 32c.
The content ratio with respect to 2 is preferably 10 to 80% by weight. In particular, a non-woven sheet is used as the backing material 32, and a large number of loops 32a to be female engaging parts are left in the non-woven sheet 32, while a male engaging element is molded in the groove 21 of the cushion material 2. When the cushion member 2 is covered with the seat cover 3 and the male / female engaging elements can be engaged with each other, the nonwoven fabric sheet 32 is provided with a large number of loops 32a to be female engaging portions. In order to leave it, the content ratio of the modified polyester fiber 32c to the nonwoven fabric sheet 32 is set to 80% by weight or less, and the residual ratio of the fiber made of regular polyester is at least 2.
It is necessary to secure 0% by weight or more. Further, when the content ratio of the modified polyester fiber 32c is 10% by weight or less, the mold formability of the seat cover 3 becomes insufficient. Therefore, the content ratio of the modified polyester fiber 32c to the backing material 32 is 10 to 10.
The optimum ratio is 80% by weight.

The seat cover 3 having a shape that matches the surface shape of the cushion material 2 with the cover material 34 described above.
1, that is, the seat cover 3 having a plurality of protrusions 35 corresponding to the respective grooves 21 of the cushion material 2 is formed along the surface shape of the cushion material 2, and the seat cover 3 is shown in FIG. As shown, the protrusions 35 are fitted into the grooves 21 while being attached along the surface shape of the cushion material 2. At this time, a non-woven fabric sheet having a large number of loops 32a is used as the backing material 32 which is a constituent material of the cover material 34, and the loops 32a are attached to the inner bottom portions of the grooves 21 provided in the cushion material 2. If a large number of male engaging elements 22 that can be fitted are integrally molded, as shown in FIG.
The seat cover 3 is easily and surely attached to the cushion member 2 by engaging with a.

As the backing material 32, which is a constituent material of the seat cover 3, textiles or the like can be used in addition to the above-mentioned non-woven fabric sheet 32. At this time, the protrusions 35 of the seat cover 3 and Cushion material 2
Between the grooves 21 or the appropriate portions of the backing material 32 and the cushion material 2 are integrally bonded by an adhesive or the like, and the seat cover 3 is attached along the surface shape of the cushion material 2. .

The seat cover 3 using the cover material 34 described above is molded as follows. First, as shown in FIG. 5, a lower mold 4 having a plurality of concave portions 41 corresponding to the respective grooves 21 of the cushion material 2, and the concave portions 4 of the lower mold 4.
1 is used, and the cover material 34 is put in the mold 6, and the cover material 34 is contained in the backing material 32. In the temperature condition above the melting point of the modified polyester 32c,
Mold by hot pressing or cold pressing. As a result, as shown in FIG. 6, the grooves 21 of the cushion material 2 are formed.
The seat cover 3 having a plurality of protrusions 35 corresponding to the above and having a three-dimensional shape conforming to the surface shape of the cushion material 2 is formed.

Here, the modified polyester 32c is
Since it has heat melting property, it is fused and integrated with the remaining fibers forming the backing material 32 and the skin material 31 or the elastic material 33. The seat cover 3 produced in this way is shown in FIG.
The protrusions 35 are inserted into the grooves 21 while being attached along the surface shape of the cushion material 2.

Next, a specific production example will be described.
As the backing material 32 of FIG. 2 (A), the composite fiber 3 having a core-sheath structure is used.
By mixing 2d and regular polyester fibers, a non-woven fabric formed from 15% by weight of modified polyester and 85% by weight of regular polyester, which starts softening at about 80 ° C., is produced, and a backing material made of this nonwoven fabric is produced. 32 and a skin material 31 made of a 100% polyester raised fabric were applied to the back surface of the former by heating with a solution type polyurethane adhesive by a roll coater method, and then adhered and integrated to form a cover material 34. . Then, after cutting the cover material 34 into a predetermined size, the cover material 34 is put into the molding die 6 of FIG. 5, molded while heating at a temperature of 120 to 180 ° C. for 1 to 2 minutes, and then cooled to room temperature. Thus, the seat cover 3 shown in FIG. 6 was obtained.

The skin material 31 and the backing material 3 shown in FIG.
The case of using the cover material 34 in which the elastic material 33 is interposed between the two is as follows. By using a urethane foam sheet having a thickness of 5 mm as the elastic material 33 of FIG. 2 (B) and mixing the composite fiber 32d having a core-sheath structure and the regular polyester fiber as the backing material 32, 1
A nonwoven fabric formed of 5% by weight modified polyester and 85% by weight regular polyester which starts softening at about 80 ° C. is prepared, and the backing material 32 made of this nonwoven fabric and the elastic material 33 are joined by needle punching. Integrated. Furthermore, the surface of the elastic material 33 is coated with polyester 10
A cover material 34 is formed by joining and integrating a skin material 31 made of 0% raised fabric by a frame laminating method (heat welding method).
Was formed. Then, after cutting the cover material 34 into a predetermined size, the cover material 34 is put into the molding die 6 of FIG.
The sheet cover 3 shown in FIG. 6 was obtained by molding while heating at a temperature of 180 ° C. for 1 to 2 minutes and then cooling to room temperature.

As the thermoplastic fiber having the heat fusion property, fibers such as polypropylene and polyamide can be used in addition to the above modified polyester fiber.

[0028]

As described above, the seat cover of the present invention can be molded into a shape that matches the surface shape of the cushioning material, and is different from the case of using a conventional special urethane resin. Unlike the above, it is possible to easily form the cushion material into a shape that matches the surface shape of the cushion material without requiring a special skill level for processing or deteriorating the productization rate.

Further, the seat cover can be molded into an arbitrary shape that matches the surface shape of the cushion material, and can reliably follow the surface shape of the cushion material. It is possible to obtain a design-like appearance, and it is possible to significantly expand the range of design when manufacturing the seat cushion and the like. Further, the cushioning material for the seat cover does not require a large number of fixing tools or the like to follow the surface shape of the cushioning material of the seat cover, and does not require a great deal of labor for fixing with the fixing tools or the like. The installation work on the side can be greatly simplified. Further, since the seat cover is formed into a shape that matches the surface shape of the cushion material, it is possible to change the appearance of the seat cushion or seat back when the cushion material is deformed when attached to the cushion material. It is possible to obtain stable quality.

Further, according to the production method of the present invention, 10 to 100% by weight of the thermoplastic fiber having heat fusion property with the skin material.
A cover material having a two-layer structure composed of a backing material containing, or a three-layer structure composed of a skin material, the backing material and an elastic material interposed therebetween is used, and the cover material is used as the backing material. Since the material is heated to a temperature higher than the melting point of the material to be molded, a seat cover having a shape matching the surface shape of the cushion material can be easily obtained.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view showing how a seat cover according to the present invention is attached to a cushion material.

2A and 2B are enlarged cross-sectional views showing different examples of cover materials for the seat cover.

FIG. 3 is a vertical cross-sectional view showing a material example of a backing material that constitutes the cover material.

FIG. 4 is a cross-sectional view showing an example of attaching the seat cover to a cushion material.

FIG. 5 is a cross-sectional view showing an example of a manufacturing apparatus for the cushion material.

FIG. 6 is a cross-sectional view of a seat cover manufactured by the manufacturing apparatus.

[Explanation of symbols]

2 ... Cushion material, 3 ... Seat cover, 31 ... Skin material, 32 ... Backing material, 32c ... Thermoplastic fiber having heat fusion property, 33 ... Elastic material, 34 ... ..Cover materials

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI technical display location B32B 27/12 7258-4F // B29K 105: 04 B29L 9:00 4F 31:58 4F

Claims (6)

[Claims] 1. A seat cover attached to the surface of a cushion material of a seat, comprising a skin material and 10 to 10 thermoplastic fibers having a heat fusion property.
A seat cover formed by joining a backing material containing 0% by weight and having a shape matching the surface shape of the cushion material. 2. The seat cover according to claim 1, wherein the skin material and the backing material are joined with an adhesive. 3. The seat cover according to claim 1, wherein an elastic material is interposed between the skin material and the backing material. 4. A method of manufacturing a seat cover, which is attached to the surface of a cushion material of a seat, wherein a thermoplastic fiber having thermal adhesiveness is provided on the back surface of the skin material.
-100% by weight of the backing material is joined to form a cover material, and the cover material is heated to a temperature above the melting point of the backing material and molded into a shape that matches the surface shape of the cushion material. Of manufacturing a seat cover. 5. The method of manufacturing a seat cover according to claim 4, wherein the skin material and the backing material are joined with an adhesive. 6. The method of manufacturing a seat cover according to claim 4, wherein an elastic material is bonded between the skin material and the backing material to form a cover material.