JPH069830B2 - How to construct a composite cushion - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention maintains a suitable cushioning property and shape of a foam cushion body used for a transportation-related seat, furniture, bedding, etc. for a long period of time, and has a good seating ability. The present invention relates to a method for constructing a composite cushion body in which a high-density foam-bonded reinforcing fabric having a special structure having a spring function for sufficiently exerting a feeling and a soft suspension function is embedded and integrated in a foam cushion body.

[Conventional technology]

As a conventional example of the structural system and geometrical relation of the present invention,
The following configurations are known.

For example, (a) Japanese Patent Application Laid-Open No. 61-234806 discloses a composite cushion body. In the claims, "25% compression hardness (according to JIS K6401) is 14 kg, which is the same as a cushion body having a compression hardness of 15 kg / 200 mm or more.
/ 200 mm or less cushion body and a laminated cushion body with a plate-like body interposed therebetween. ", But this system is a composite cushion body in which a plate-shaped body is interposed and laminated between two conventional cushion bodies having different compression hardnesses.

(b) Utility Model No. 61-172560 (automobile seat structure) In this example, as described in the scope of claims for utility model registration, "the frame, the fiber member stretched over the frame, and the fiber member A seat structure for an automobile having a laminated urethane foam layer, wherein the fibrous member is made of highly elastic fiber having elasticity, and the urethane foam partially penetrates into the fibrous member. It is an automobile seat structure characterized by being integrated by a polymerization reaction. "In summary, it is an automobile seat structure in which a fiber member is stretched over a frame and a urethane foaming undiluted solution is injected and integrated. .

(c) Japanese Utility Model Laid-Open No. 61-170360 (Cushion body for seat) In this example, as described in the scope of claims for utility model registration, "the mesh member 2 made of stretched plastic filament is used as the main body 1 made of polyurethane foam. The gist of the present invention is "a cushion for a seat, which is characterized in that the surface reinforcing layer 3 is formed by embedding and integrating the entire surface in a surface layer portion."

As described above, the conventional reinforcement structure of the cushion body is composed of a plate-like body or a plain weave structure which has almost uniform longitudinal and lateral support, and all conventional reinforcement concepts are seated irrespective of the motion or displacement of the seated person. It is constructed by the idea of supporting the parts evenly.

[Problems to be Solved by the Invention]

As described above, all the conventional reinforcing members to be inserted into the cushion body are assembled by the concept of evenly supporting the seated portion of the seated person. Therefore, although the amount of sinkage differs depending on the rigidity of the reinforcing material, the yarns and filaments that make up the conventional reinforcing material are composed of longitudinal and transverse materials of the same series that are combined in a plain weave structure to produce longitudinal and transverse fibers. Have the same degree of freedom of movement, have a strong sense of bulging, are apt to feel the vibrations of the car such as the engine, and have poor riding comfort, and are reinforced when the seated person is shaken or displaced. The foam has a large degree of feel to the support, and the support itself has no freedom, is fixed, and tends to sink in parallel with the foam of the low-density cushion foam. The influence of creep is large, and the feel of the support also increases with the passage of time.

Therefore, it is important to solve the setting of a reinforcing material which is a reinforcing material capable of maintaining the shape of the cushion body for a long period of time and which can behave in conformity with the motion of the seated person on the seat. With a strong coupling force and selection of a combined body that can make a smooth free operation without making fixed and unsmooth operation of each part of the reinforcing material that strongly and integrally contacts at the correct position. Need to be buried.

That is, although it has supportability, the feel of the support is softened, and an appropriate spring feeling and sinking feeling can be obtained at the time of sitting, and at the same time, there is no bottoming feeling or bulging feeling. An object of the present invention is to provide a method of forming a composite cushion body that is comfortable to ride and that does not easily transmit vehicle vibrations.

[Means for Solving the Problems]

In order to achieve the above-mentioned object, the reinforcing member of the constitution method of the present invention eliminates the conventional plate-like body or plain weave structure, mainly comprises the weft yarn of the elastomeric monofilament, and the weft yarn is the warp yarn of the staple fiber. , Weft yarns are connected in a straight line in parallel, and one or more layers of reinforcing fabric are joined at their intersections in advance by injecting a foaming compound liquid for soft high-density foam in the mold cavity. Then, the warp yarns and the weft yarns are strongly connected by a high-density foam, and the high-density foam-bonded reinforcing fabric embedded and molded in a required plate shape is used as a reinforcing member. That is, when such a reticulated fiber material is directly inserted at the time of seat formation of the cushion foam and the foaming compounding liquid is injected and integrated, the liquid around is bad at the time of integral foaming, and a void (Void) or the like is generated, resulting in a completely uniform distribution. Since it is difficult to obtain a monolithic structure, a high-density foam-bonded reinforcing fabric is preformed by pressure molding alone. This fully integrated, high density foam bonded reinforced fabric is placed within the cushion body by providing a foam formulation for the cushion foam that accommodates a lower density upper layer in the lower cavity than the foam used in the above fabric. After injecting a liquid amount, closing the upper mold and performing heat foaming molding, immediately after the tack free time or rise time of the foamed product, the upper mold is opened to form the foam for the upper layer part, and the above-mentioned preformed necessary The high-density foam-bonded reinforcing fabric in the shape is coated with a foaming adhesive, the fabric is pressure-bonded to the foam, and the foamable compounding liquid for cushion foam is injected to form the upper mold for the lower layer molding. The composite cushion body is constructed by closing, heat foaming, and continuously integrally molding.

When the upper layer portion of the cushion body has a planar shape such as a cushion foam for bedding, the upper layer portion can be molded by using a slab-shaped foam material in addition to the injection foaming. That is, the molding of the cushion foam of the upper layer is a foam for the upper layer obtained by cutting the foam material having a lower density than the foam of the above-mentioned fabric used in advance to have a desired shape by slab (Slab), This is set in the lower mold to form a foam for the upper layer portion, and the composite cushion body is constructed in the same manner as described above.

The normal range of use of the weft elastomeric monofilament is preferably such that the fiber diameter is about 0.125 mm or more and 1.5 mm or less. As for the number of fabrics to be driven, an appropriate combination is used depending on the application. In addition, as the warp yarn of the staple fiber, a non-elastomeric yarn or an elastomeric yarn is appropriately selected depending on the application.

[Action]

The composite cushion body configured as described above uses, as its reinforcing support, a special fabric having extremely large degrees of freedom in which the weft threads of the elastomeric monofilament are connected in a straight line in parallel, and the warp threads of the staple fibers are connected to each other. The straight weft is a high-density foam because the plate-shaped high-density foam-bonded reinforcing fabric of the required shape is embedded in the soft high-density foam under pressure and completely integrally molded. Since each of the weft threads is evenly bonded in the cushion foam of low density without being partially submerged,
It has a large degree of freedom to move sequentially and move up and down in a suitable manner locally, and it exhibits a suitable cushioning behavior that adapts to the sway of the seated person, and there is no supportive feel and a soft contact feeling is formed. To be done. Further, since the fabric is molded into a plate shape with a high-density foam and is bonded at a predetermined position, the fabric has an excellent shape-retaining property and retains the shape of the seat for a long time.

〔Example〕

Example-1 FIG. 1 is a perspective view showing an example of a fabric F used for a reinforcing member having a spring mechanism of the present invention, and FIG. 2 is a view showing a high density foam-bonded reinforcing fabric provided in a lower portion of a seat portion. FIG. 3 is a schematic plan view showing the internal structure by cutting out a part of the seat portion.

In the figure, F shows a fabric system having a special structure used in the present invention. In the fabric used in this example, 1 is a weft yarn made of stretched polyester elastomeric monofilament, and 2 is a polyester staple. It is a warp yarn made of fibers (textured yarn of spinnable short fibers produced in a short length). In this example, the weft elastomeric monofilament has a fiber diameter of about 4 mm and the warp staple fiber has a fiber diameter of about 350 denier. 3 is a soft high-density foam-bonded reinforcing fabric (as described above, a foaming compound liquid for soft high-density foam is strongly injected under pressure into the cavity of one or more layers of the reinforcing fabric in advance in the mold cavity. It is obtained by embedding into a required plate-like shape by connecting to 4.) 4 is an upper layer portion of the composite cushion body, 5 is a lower layer portion of the composite cushion body, and arrow a is a setting direction of the weft thread 1,
ja is a joint between the upper layer 4 and the lower layer 5.

The construction method of this example is such that a lower mold cavity for molding a composite cushion body is injected with a foaming compounding liquid amount for a cushion foam corresponding to the upper layer portion, which has a lower density than the high density foam of the reinforcing fabric, and 1 Close the upper mold, heat foam molding to mold the upper layer portion 4, and open the first upper mold immediately after the tack free time or rise time of this foam,
A foaming adhesive (foaming compounding liquid for low-density cushion foam) is applied to the pressure-bonded portion of one or more layers of the high-density foam-bonded reinforcing fabric 3 having a predetermined shape, and the foam-bonded reinforcing fabric 3 is formed as described above. The upper layer portion 4 is pressure-bonded and adhered, the foaming compounding liquid for the cushion layer of the lower layer portion is injected, the second upper mold is closed, and heat foaming is performed to form the lower layer portion 5 to continuously and integrally form the whole. To form a composite cushion body.

Example-2 FIG. 4 is a schematic sectional view of another example of the composite cushion body of the present example, and FIG. 5 is a schematic plan view of the same.

In this example, in addition to the structure of Example-1, in order to further improve the supportability of the raised bank portions on both sides of the seat and at the same time to satisfy the soft contact feeling, the banks on both sides of the cushion foam of the seat are provided. The weft yarns 1 of the high-density foam-bonded reinforcing fabric 3 formed into a desired curved shape are embedded and integrated in an arch shape in the direction of arrow a. The configuration method is
Lower mold cavity (Cavit
Into (y), inject a foaming compounding liquid amount for the cushion foam corresponding to the upper layer, which has a lower density than the high-density foam of the reinforcement-like fabric, closes the first upper mold, and heat foams to form the upper layer 4 And the first upper mold is opened immediately after the tack free time or the rise time of the foamed material of the upper layer part,
A foaming adhesive is applied to the pressure-bonded portion of the high-density foam-bonded reinforcing fabric 3 having a predetermined shape (curved shape and plane shape) that has been formed in advance, and the foam-bonded reinforcing fabric 3 is pressure-bonded to the upper layer portion 4 to form a cushion. A composite cushion body is constructed by injecting a foamable compounding liquid for foam, closing the second upper mold, and performing heat foam molding to form the lower layer portion 5 and integrally molding the whole. In the figure, Ja is a joint between the upper layer 4 and the lower layer 5.

Example-3 FIG. 6 is a schematic sectional view of another example of the composite cushion body of this example, in which a high-density foam-bonded reinforcing fabric 3 is set on the entire surface between the upper layer portion 4 and the lower layer portion 5 of the seat. It was done.

FIG. 7 is a schematic plan view of the same, in which the high-density foam-bonded reinforcing fabric 3 sets the weft threads 1 in the direction of arrow a.

The configuration method is performed in the same procedure as in the first embodiment.

Example-4 This example shows an example of a simple configuration method in the case of a planar shape such as a cushion foam for bedding.

The cushion foam of the upper layer part 4 of the cushion body of this example is formed by cutting a foamed slab-like foam material, which has a lower density than the foam used for the reinforcement-like fabric, into a required shape. The composite cushion body is set in a cavity of a lower mold to form a foam for the upper layer portion 4, and an adhesive is applied to the press-contact portion of the high-density foam-bonded reinforcing fabric 3 having a predetermined shape which has been formed in advance, and the fabric is formed. Is pressure-bonded to the foam for the upper layer 4, the foaming compounding liquid for the cushion foam of the lower layer 5 is injected, the other upper mold is closed, and the heat-foam molding is performed to form the lower layer 5. The composite cushion body is formed by molding.

〔The invention's effect〕

The composite cushion body obtained by the configuration method of the present invention has the function and function as described in the above-mentioned action section, so that a proper spring feeling and a soft contact feeling adapted to shaking can be obtained when sitting, and With no such a feeling of bulging or bottoming, and excellent damping characteristics, propagation of vibrations of a vehicle such as an engine is blocked, and a suitable riding comfort can be obtained. In addition, a fabric with a special structure is completely connected in a plate shape by pressure molding with a soft high-density foam in advance, and while it has a suitable degree of freedom, it has excellent shape retention and low density. It is effective in maintaining the cushion shape of the cushioning foam for a long period of time.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a fabric used in the present invention, FIG. 2 is a schematic sectional view of an example of a composite cushion body according to the structure of the present invention, and FIG. 3 is a partially cutaway internal structure. 4 is a schematic sectional view of a composite cushion body showing another embodiment, FIG. 5 is a schematic plan view of the same, and FIG. 6 is a composite cushion body showing another embodiment. FIG. 7 is a schematic sectional view of FIG. F ... Reinforcing fabric 1 ... Weft (elastomeric monofilament) 2 ... Warp (staple fiber) 3 ... High density foam-bonded reinforcing fabric 4 ... Upper layer, 5 ... Lower layer

Continuation of the front page (51) Int.Cl. ⁵ Identification code Reference number within the agency FI Technical display area // F16F 1/36 B 8917-3J B29K 105: 04 105: 08 B29L 31:58 4F

Claims (2)

[Claims] 1. A reinforcing fabric mainly composed of a weft of an elastomeric monofilament as a reinforcing material contained in a composite cushion body, the wefts being connected by a warp of staple fibers in a straight line in parallel and joined at the intersections thereof. Using a high-density foam-bonded reinforced fabric in which one or more layers of the above are embedded and molded in the required shape in the shape of a plate under the injection pressure of the foaming compounding liquid for soft high-density foam in the fabric mold in advance. , The upper part of the cushion body is injected into the cavity of the lower mold with a foaming compounding liquid for cushion foam having a lower density than the foam used for the above fabric and corresponding to the upper part, and the first upper mold is closed. Then, heat foaming is performed, and immediately after the tack free time or rise time of the foam is finished, the first upper mold is opened to open the foam for the upper layer portion. Foamed adhesive is applied to the pressure-bonded portion of the high-density foam-bonded reinforcing fabric having the above-mentioned preformed shape, and the fabric is pressure-bonded to the foamed body to form a foamable compound for the cushion foam of the lower layer. A method for constructing a composite cushion body, which comprises injecting a liquid, closing a second upper mold, performing heat foam molding to form a lower layer portion, and continuously and integrally molding. 2. A reinforcing fabric mainly composed of weft yarns of an elastomeric monofilament as a reinforcing material contained in a composite cushion body, the weft yarns being connected by a warp yarn of staple fibers in a straight line in parallel and joined at their intersections. Using a high-density foam-bonded reinforced fabric in which one or more layers of the above are embedded and molded in the required shape in the shape of a plate under the injection pressure of the foaming compounding liquid for soft high-density foam in the fabric mold in advance. , The upper part of the cushion body is set in the lower mold cavity with the foam material for slab processing cut into the required shape corresponding to the upper layer part of lower density than the foam used in the above fabric to form the upper part foam Then, the above-mentioned high-density foam-bonded reinforcing fabric of the required shape that has been preformed above, and apply an adhesive to the pressure contact portion, The fabric is pressure-bonded to the foam for the upper layer, the foaming compounding liquid for the cushion foam for the lower layer is injected, the upper mold for the lower layer is closed, and heat-foam molding is performed to form the lower layer, which is integrated. A method for constructing a composite cushion body, which comprises molding.