JPH0688353B2 - A method of manufacturing foam pad - Google Patents
A method of manufacturing foam padInfo
- Publication number
- JPH0688353B2 JPH0688353B2 JP1106825A JP10682589A JPH0688353B2 JP H0688353 B2 JPH0688353 B2 JP H0688353B2 JP 1106825 A JP1106825 A JP 1106825A JP 10682589 A JP10682589 A JP 10682589A JP H0688353 B2 JPH0688353 B2 JP H0688353B2
- Authority
- JP
- Japan
- Prior art keywords
- woven fabric
- resin
- sheet
- laminated
- 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.)
- Expired - Lifetime
Links
Landscapes
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
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
よび衣服用キルティ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。Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a foam foam pad suitable for a seat of a chair, a backrest, an interior material for a vehicle, a quilting place for clothes, 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
ケーツ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、ポリウレタン等のフォームパ
ッドを積層し、その上を布帛やレザー等の可とう性表皮
シートで被覆したものが、また衣服や寝具用クッション
として表裏の布帛間に上記のフォームパッドを挟み、キ
ルティングにより一体化したものが使用されている。ま
た、上記のフォ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）。(Prior Art) Foam such as polypropylene, polyethylene, polyvinyl chloride, polyurethane, etc. on a plate-like substrate such as a hardboard or fiberboard as a seat for a chair, a backrest, an interior material for passenger cars, and an adhesive material for attachés or trunks. The one with the pad laminated and the one covered with a flexible skin sheet such as cloth or leather, or the one with the above foam pad sandwiched between the cloth on the front and back as a cushion for clothes or bedding and integrated by quilting It is used. Further, it is known to use, instead of the foam pad, an elastic pad obtained by coating a filament of a non-woven fabric made of a filament of synthetic fiber and its entangled portion with a thermoplastic resin foam having closed cells. (Actual exploitation 63
-124122 publication).
（発明が解決しようとする課題） しかしながら、従来は、上記のフォ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、キルティング状の
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
ティ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、上記のフォームパッドや弾性パッドに立体感のすぐ
れたキルティ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、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。(Problems to be Solved by the Invention) However, conventionally, the foam pad or the elastic pad is laminated between any base material and the skin sheet in a bulky state after the foaming treatment. When the peripheral edge of the laminate is finished by high-frequency welding or stitching, or when a quilted pattern is formed, the above laminate must be compressed along the peripheral edge and the quilted pattern line. This compression is troublesome and sufficient. There are problems such as inability to compress, lack of a three-dimensional effect, and unsatisfactory wrinkles due to insufficient tension of the skin sheet. Further, in order to provide the above-mentioned foam pad or elastic pad with a quilted pattern having an excellent three-dimensional effect, casting foaming is required, and for that purpose, a die and other equipment must be prepared. Further, since the pad in the laminated body has already been foamed, it has a large bulkiness and is inconvenient to carry and handle from the foaming step to the laminating 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、キルティング模様の形成
を容易にし、キルティ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 facilitates the finishing of the peripheral edge and the formation of a quilted pattern by performing foaming after the completion of lamination or after product assembly, increases the three-dimensional effect of the uneven pattern due to quilting, etc., and improves the tension of the skin sheet to improve wrinkling. It prevents the occurrence of the above and eliminates the use of 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、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
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。(Means for Solving the Problems) In order to solve the above problems, in the present invention, an adhesive containing unexpanded microballoons in a nonwoven fabric composed of latently crimpable synthetic fiber filaments that develop crimping by heating. Of a filament and its entangled portion which are impregnated with a functional resin liquid and dried to form the above-mentioned non-woven fabric are coated with the above-mentioned adhesive resin liquid, and the obtained resin-impregnated non-woven fabric is provided with a flexible skin such as cloth, leather or a plastic sheet. Stack the sheets,
At least the peripheral edge of the obtained laminated sheet is fastened by fastening means such as stitching, high-frequency welder, pinching, etc., and the above-mentioned laminated sheet is heated in a state in which the expansive force of the microballoon located in the fastened portion is reduced or lost. The micro-balloons other than the tightened portion are expanded to form the resin-impregnated non-woven fabric in a bulky shape.
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からなり、加熱によ
り巻縮を発現する潜在巻縮性のフィラメントである。な
お、上記フィラメントの好ましい繊度は、1.0デニール
以上、特に5.0デニール以上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 filament constituting the above-mentioned non-woven fabric is a latent crimping filament which is made of synthetic fiber such as polyester type, polyamide type, polyacrylic type, polyvinyl chloride type and polyolefin type and which causes crimping by heating. The preferable fineness of the filament is 1.0 denier or more, particularly 5.0 denier or more and 10.0 denier or less,
If it is too thin, 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/m2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。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。The above filaments are arranged at random to form a web, and the webs are stacked so that the basis weight is, for example, 50 to 150 g / m 2, and the contact portions between the filaments are heat-bonded, preferably fixed by powder bonding. As a result, a non-woven fabric is formed. It should be noted that the filaments can be entangled with each other by needle punching to form a nonwoven fabric. In this case, the needle density can be made coarse to the extent that the entangled portions of the filaments are misaligned when the microballoons are heated and foamed. preferable.
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、増粘剤および助剤からなり、これにマイ
クロバルーンを配合し、攪拌して得られ、100〜180℃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。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、80/20〜9
9/1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 adhesive resin liquid impregnated into the above-mentioned non-woven fabric consists of a thermoplastic adhesive resin, a thickener and an auxiliary agent, which is mixed with a microballoon and obtained by stirring, and heated at 100 to 180 ° C. By this, the independent bubbles are generated by the expansion of the microballoon. The microballoon is made of any one or more resins having gas barrier properties such as polyvinyl chloride, polyvinylidene chloride, and polyacrylonitrile, and is filled with a gas such as isopropane and isobutane. Is. The preferable mixing ratio of the microballoon and the adhesive resin solid component is 80/20 to 9
It is 9/1, and particularly preferably 90/10 to 96/4, and when the compounding ratio of the microballoon is small, the expansion ratio is insufficient and the impact resilience is reduced, and when it is too large, the adhesive force of the adhesive resin liquid is low. It becomes insufficient and the workability deteriorates.
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20〜10
0％、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 adhesive resin liquid is impregnated into the above nonwoven fabric by a means such as dipping, coating or spraying, and squeezing it if necessary,
Preferably, the impregnation amount (solid content amount) is 20 to 10 of the weight of the nonwoven fabric.
The filament is adjusted to 0%, preferably 40 to 70% and dried, and the filaments and the entangled portions constituting the nonwoven fabric 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とう性シート、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 laminated on the surface of the obtained resin-impregnated nonwoven fabric is a flexible sheet such as woven fabric, knitted fabric, leather, and plastic sheet, and if desired, the same flexible sheet as the above on the back surface of the resin-impregnated nonwoven fabric. Alternatively, base materials of arbitrary shapes such as hard boards, fiber boards, pipes, etc. can be stacked.
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
部をキルティングの模様状に接合され、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られる。な
お、表皮シートおよび樹脂含浸不織布の二者を重ね、貼
合せ、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 above-mentioned skin sheet and resin-impregnated non-woven fabric are laminated,
Preferably, it is joined along at least the peripheral portion thereof by a high frequency welder or suture, and further, if necessary, the central portion is joined in a pattern of quilting so that the microballoon located at the joined portion is destroyed or It is tightened to the extent that foaming does not occur. It should be noted that the skin sheet and the resin-impregnated non-woven fabric are overlaid, laminated, and joined by any other means, and the polymerized sheet is adhered to a base material having an arbitrary shape, preferably a structural material such as a plate or a pipe. It is possible to bond at least the peripheral portion of the polymerized sheet to the above-mentioned base material so that the microballoons located at the bonded portion are broken or tightened to such an extent that the microballoons do not foam.
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、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。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。Then, the laminate of the above-mentioned skin sheet, resin-impregnated non-woven fabric and substrate is placed in an oven and heated at 100 to 180 ° C. by a steam heater, an infrared heater, high frequency dielectric heating or the like to 0.5.
It is heated for ~ 5.0 minutes, whereby the microballoons in the resin-impregnated non-woven fabric are foamed, and the resin-impregnated non-woven fabric exhibits bulkiness. 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、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押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。A thermoplastic sheet is used as the skin sheet, and the skin sheet and the resin-impregnated non-woven fabric of the thermoplastic sheet are overlapped, preferably with a hot melt adhesive such as a thermoplastic resin film interposed therebetween, and this polymerized sheet is used. The above-mentioned skin sheet is attached to the mold for vacuum molding so as to face the mold recess, and its peripheral portion is pressed and fixed by the upper mold and tightened to the extent that foaming of the microballoons located in the peripheral portion does not occur,
In this state, the polymerized sheet can be vacuum-molded.
（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
成の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
ずれが生じると共に、不織布の構成フィラメントが巻縮
を発現し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、表皮
シートおよび可と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、表皮シー
トを積層、接合後に発泡させるので、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、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。(Operation) By heating the laminated body in an oven, the microballoons in the expandable resin covering the filaments of the non-woven fabric expand, causing a gap in the bonding or entanglement part of the filaments, and the non-woven fabric structure. The filament expresses crimp and the resin-impregnated non-woven fabric expresses bulkiness, pressure is applied to the inner surface of the skin sheet and the base material of the laminate, the base material made of the skin sheet and the flexible sheet expands, A foam foam pad is manufactured. Since the filler of the obtained foam-filled foam pad is formed of the foamed synthetic resin and the non-woven fabric having the closed cells of the microballoons where there is no escape of gas, it is a normal foamed synthetic resin having the open cells or the closed cells. However, the compression resistance is increased, the compression ratio is lowered, and the bottoming feeling is eliminated, as compared with the case where the foamed resin having no microballoon is used for the pad. Then, since the skin sheets are laminated and joined and then foamed, the base material made of the skin sheet and the flexible sheet is stretched in all directions by the internal pressure caused by the foaming, and the slack and wrinkles are extended. Moreover, the portion that has been joined in a line shape by suturing, high-frequency welder, or the like and has lost its foaming function does not exhibit bulkiness at all, and is retained in the state before foaming, so it is not a bulkiness expressing portion. The difference between the unevenness is markedly shown. Furthermore, by adjusting the filling density of the microballoons according to the purpose, it is possible to easily set the porosity, the compression elastic modulus and the compression rate of the product.
なお、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。When vacuum forming the skin sheet at the same time as the heat treatment, unevenness is formed on the skin sheet according to the shape of the mold, and the microballoons in the resin-impregnated non-woven fabric partially expand with 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 previously interposed in the form of a film between the skin sheet and the resin-impregnated nonwoven fabric, Simultaneously with vacuum forming, both 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/m2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」）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F30」）94.5g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753」）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「D251」）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 the non-woven fabric, a heat-fusion non-woven fabric (product name: "Ultraloft LP108" manufactured by Lo & Bonner Co., Ltd.) made of latently crimpable polyester filament and having a basis weight of 108 g / m 2 was used. On the other hand, 94.5 g by weight of microballoon (Matsumoto Yushi-Seiyaku Co., Ltd., trade name "Matsumoto Microsphere F30"), vinyl acetate / ethylene copolymer emulsion for adhesion (Sumitomo Chemical Co., Ltd., trade name "Sumikaflex") 753 ") 5 parts by weight, 0.5 parts by weight of an acrylic acid ester-based thickener (trade name" D251 "manufactured by Kyouka Chemical Industry Co., Ltd.) and a small amount of aqueous ammonia were mixed to adjust the viscosity to 500 cp. An aqueous solution having a concentration of 20% 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％、ウエット重量400
g/m2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1mm、重量170g/m2であった。Immerse the above heat-bonded nonwoven fabric in this foamable resin liquid, squeeze through a nip roll, draw ratio 300%, wet weight 400
Adjust to g / m 2 , put this resin-impregnated non-woven fabric in the oven,
Dried at 65 ° C. The dried resin-impregnated nonwoven fabric had a thickness of 1 mm and a weight of 170 g / m 2 .
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
それぞれサンドイッチ状に挟み、キルティング加工を施
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、キルティングによる縫合部
の厚さ1.0mm、膨張部分の厚さ10.0mmの鮮明な立体感を
有し、クッション性にすぐれ、外観の美しい、かつ底づ
き感のないクッション材が得られ、自動車の室内クッシ
ョン材として好適であった。The above resin-impregnated non-woven fabric is sandwiched between a woven fabric base material and a knitted skin sheet, and between a woven fabric base material and a woven fabric skin sheet, and subjected to quilting, and then 120 When heated in an oven at ℃ for 2 minutes, the microballoons are foamed and the constituent filaments of the non-woven fabric develop crimps. The sewn part by quilting has a thickness of 1.0 mm and the expanded part has a thickness of 10.0 mm. A cushion material having a feeling, an excellent cushioning property, a beautiful appearance and a bottomless feeling was obtained, and it was suitable as an indoor cushion material for automobiles.
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。Also, a Raschel knitted skin sheet is laminated on the dried resin-impregnated non-woven fabric, a bag of the size of the backrest of a passenger car seat is made using this laminated sheet, and the frame of the backrest is used as a base material. The bag was attached, the mouth of the bag was fixed to the lower end of the frame with studs, and the product was produced with only the foaming treatment left. Then, heat treatment was performed at 120 ° C. for 2 minutes in an oven. Wrinkles generated at the corners etc. when sewing the above bag disappears, bulges increase, rich in three-dimensional feeling,
A backrest excellent in 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1.0mm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65mm、長さ310m
m）を真空成型用の最大深さ40mm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上型を当接し、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, a 1.0 mm-thick synthetic leather sheet made of thermoplastic synthetic resin was pasted on the surface of the dried resin-impregnated non-woven fabric as a skin sheet, and this polymerized sheet (width 65 mm, length 310 m)
m) is placed on a mold having a recess for vacuum forming having a maximum depth of 40 mm with the skin sheet facing downward, the mold is closed, and a flat upper mold is brought into contact with the back surface of the resin-impregnated nonwoven fabric, and The periphery of the polymerized sheet is clamped and fixed by pressure bonding, and then the inside of the mold is depressurized while heating the above mold to vacuum form the skin sheet into the shape of the mold and expand the microballoons in the resin-impregnated nonwoven fabric. Then, the above-mentioned non-woven fabric was formed into a space shape of a mold, and thereafter, a molded product was taken out and the back surface of the foam pad containing the above-mentioned non-woven fabric was bonded 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、ほ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生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を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、しか
も不織布に潜在巻縮性フィラメントを用いているため、
発泡処理の際に上記フィラメントが巻縮を発現して製品
のかさ高性が一層増大する。そして、積層時にキルティ
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。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。(Effect of the Invention) Since the present invention is a method of laminating a resin-impregnated non-woven fabric impregnated with an adhesive resin with a skin sheet and heating the foamed resin after the product shape is almost adjusted, closed cells are generated in the foamable resin. Compared to the conventional method of laminating after foaming treatment, joining and arranging into the product form, the work of laminating and joining is easier,
And because the skin sheet is strained by the internal pressure accompanied by foaming, wrinkles and sagging are eliminated, the appearance of the product becomes beautiful, and since the latent crimpable filament is used for the nonwoven fabric,
During the foaming process, the filaments develop crimp, which further increases the bulkiness of the product. When a quilted pattern is formed during stacking, a concave-convex pattern excellent in three-dimensional effect with a large difference between the concave portion and the convex portion can be obtained. Further, when heating a laminated sheet of a resin-impregnated non-woven fabric and a skin sheet, by vacuum-forming the skin sheet at the same time, foam molding of the resin-impregnated non-woven fabric can be performed at the same time. Compared with the need for casting a foaming urethane liquid after vacuum forming the skin sheet, the molding process is halved.
Claims (4)
繊維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。1. A non-woven fabric comprising latently crimpable synthetic fiber filaments which exhibit crimping upon heating is impregnated with an adhesive resin solution containing unexpanded microballoons and dried to form a non-woven fabric and a filament thereof. The entangled portion is coated with the above adhesive resin liquid, the obtained resin-impregnated non-woven fabric is laminated with a flexible skin sheet such as cloth or leather or a plastic sheet, and at least the peripheral portion of the obtained laminated sheet is sewn, The laminated sheet is heated under the condition that the expansion force of the microballoon located at the tightening portion is reduced or lost by tightening with a tightening means such as a high-frequency welder or a pinching member, and the microballoons other than the tightening portion are expanded. A method for producing a foamed foam pad, which comprises forming an impregnated non-woven fabric into a bulky shape.
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。2. The method for producing a foam-filled foam pad according to claim 1, wherein a resin-impregnated non-woven fabric is laminated between a skin sheet and an arbitrary substrate.
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。3. A resin-impregnated non-woven fabric and a skin sheet are laminated to form a bag, and the bag is adhered to a base material of an arbitrary shape, whereby the resin-impregnated non-woven fabric is laminated between the skin sheet and the base material. The method for manufacturing the foamed foam pad according to claim 2.
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。4. The method for producing a foamed foam pad according to claim 1, wherein when the laminated sheet of the resin-impregnated non-woven fabric and the skin sheet is heated, the skin sheet is vacuum-formed at the same time.
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 JPH02286225A (en) | 1990-11-26 |
| JPH0688353B2 true 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) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2773006B2 (en) * | 1992-04-10 | 1998-07-09 | 嘉一 山口 | Cushion material and manufacturing method thereof |
| JP4328822B1 (en) * | 2008-03-28 | 2009-09-09 | 中川産業株式会社 | Manufacturing method of thermally expandable base material for vehicle interior and manufacturing method of base material for vehicle interior using the same |
| JP5391436B2 (en) * | 2008-04-01 | 2014-01-15 | 白金化成株式会社 | Products using laminated sheets |
| US20100199406A1 (en) | 2009-02-06 | 2010-08-12 | Nike, Inc. | Thermoplastic Non-Woven Textile Elements |
| US8906275B2 (en) | 2012-05-29 | 2014-12-09 | Nike, Inc. | Textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements |
| US9682512B2 (en) | 2009-02-06 | 2017-06-20 | Nike, Inc. | Methods of joining textiles and other elements incorporating a thermoplastic polymer material |
| US20130255103A1 (en) | 2012-04-03 | 2013-10-03 | 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 |
| EP2778117B1 (en) * | 2013-03-12 | 2015-05-13 | Boxmark Leather d.o.o. | Multi layered covering material and process for making multi layered covering material for elements making furniture more comfortable comprising upholstery, cushions, blankets, and similar elements |
Citations (1)
| 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 |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0445871Y2 (en) * | 1987-02-07 | 1992-10-28 | ||
| JPH0353862Y2 (en) * | 1987-02-24 | 1991-11-26 |
-
1989
- 1989-04-26 JP JP1106825A patent/JPH0688353B2/en not_active Expired - Lifetime
Patent Citations (1)
| 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 |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH02286225A (en) | 1990-11-26 |
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