JPH0793992B2 - Breathable sheet cushion and method for producing the same - Google Patents

Description

TECHNICAL FIELD The present invention relates to a moisture permeable seat cushion provided with a moisture permeable film, which is used for vehicles, ships, aircraft, furniture, etc., and a method for manufacturing the same.

[Conventional technology]

Conventionally, the structure of the seat cushion system is generally of the following type.

For example, (a) Japanese Patent Laid-Open No. 60-36085 discloses a "method for manufacturing a cushion body having a cloth surface layer" used for cushion bodies such as seats and headless. The gist of the construction is "a layer of cloth is laminated on one surface and a skin layer of non-breathable or air-impermeable material is provided on the other side of the surface of the elastic foam body is sewn or welded to form a desired bag shape. The method for producing a cushion body having a surface layer of cloth, which is characterized by injecting a liquid foamed plastic material into the bag and foaming the material into a desired shape. "

That is, as the skin material, a laminate of fabric + foam + skin layer (non-breathable) is sewn or welded into a desired bag shape, which is set in a mold, and a liquid foamed plastic raw material is injected into the bag. Then, it is formed into a desired shape by foaming.

Further, as a constitution in which the foamed molded product and the decorative sheet are integrated, (b) Japanese Patent Application Laid-Open No. 55-19535 (a method for producing a foamed polyurethane molded product having a name and a pattern) is disclosed. The gist is "a decorative sheet made by applying an adhesive to one side of a vinyl chloride sheet with a desired pattern is applied to a female mold having the desired shape, and the surface with the adhesive is on the opposite side of the female mold. Fixed to, without vacuum softening, or after vacuum suction while heating and softening, inject a polyurethane foam resin and stack male molds, foam and cure the polyurethane foam resin to form a foam molded product, and foam With the adhesive force of the adhesive activated by the foaming heat generated when the polyurethane resin is foamed and cured, the self-adhesiveness of the foamed polyurethane resin and the heat of foaming and foaming pressure generated when foaming and curing the foamed molded product and the decorative sheet. A method for producing a foamed polyurethane molded product having a pattern characterized by being integrated. "

That is, as a skin material, using a conventional embossed vinyl chloride sheet, a desired shape by a vacuum forming method,
A polyurethane foam molded product was obtained by injecting urethane foaming undiluted solution and integrally foaming.

As a crimping method, (C) Japanese Patent Publication No. 59-40037 discloses a "manufacturing method of a seat body". The gist is, "The side surface is joined around the seating part of the seat body by mincing stitching or high frequency heating to form a bag-shaped seat surface part, and the seat surface part is formed on the lower mold having a carving symmetrical with this shape. Inversion to fix the coupling portion and heat the seating portion, and after heating,
The upper die having the same shape as the seating portion is pressed against the lower die for holding the seat surface portion to form a desired shape on the surface of the seating portion, and then the upper die is released to form the seating portion and the seating portion. Adhesive is applied to a cushioning material such as a skinless mold of urethane foam or a slab material of the same shape as the above, and the cushioning material is bonded and bonded to the seating part, taken out from the lower mold, the side part is inverted and the seat A manufacturing method of a seat body, characterized in that a body is formed, and further, a full pressing die that fits into a recess having a seating portion shape is press-fitted and held from the front side to further shape the bottom of the recess. It is.

In other words, in summary by the detailed description of the invention, "in the fabric skin, the bag-shaped seat surface portion in which the seating portion and the side surface portion are joined by sewing machine sewing or high frequency heating is heated to form a desired shape. The lower mold is pressed to form a concave and convex shape of the desired shape on the seat surface, and an adhesive is applied to the cushioning material of the concave and convex urethane foam body for fitting which is separately molded and processed. Fit and adhere to the concave and convex shape of the seat surface of the lower mold, take this out from the lower mold, reverse the woven surface skin on the side of the cushion material to the side of the cushion material to form the seat body, and further make the concave and convex pattern with the full pressing mold. A manufacturing method of a seat body that is molded sharply. "

As mentioned above, when the key points of the conventional technical configuration are picked up, (a) the one described in Japanese Patent Laid-Open No. 60-36085 states that "the back of the fabric is lined with a foam and a non-breathable skin layer, This is one in which foamed plastic is injected and integrated into a skin layer in which a woven fabric and a foam are directly adhered to each other.
The one described in Japanese Patent No. 9535 is a sheet in which an adhesive is applied to one side of an embossed vinyl chloride sheet, which is molded into a desired shape by vacuum forming and a polyurethane foam resin is injected and integrated. (C) The one described in Japanese Examined Patent Publication No. 59-40037 has a cushioning material made of urethane foam having a concave-convex pattern for fitting to a fabric skin material having a concave-convex pattern on the seating part. The seat body is formed by fitting and bonding.

[Problems to be solved by the invention]

(A) JP-A-60-36085 (method for manufacturing a cushion having a surface layer of cloth) and (B) JP-A-55 of the prior art mentioned above.
-19535 (Method for manufacturing foamed polyurethane molded products with a pattern) is integrated with the foaming raw material, and the outer skin layer is a bag made by sewing or welding a material in which a foam and a non-breathable sheet are lined on a woven fabric. It is used in the form of a sheet or in the form of a bag made by vacuum forming an embossed vinyl chloride sheet which is a non-breathable substance. As a result, the fabric adheres directly to the foam and does not provide a strong and durable bond. In addition, since the physical properties of the epidermis layer are all impermeable to moisture, there is a problem that when sitting for a long time, a feeling of stuffiness causes discomfort.

Further, in the configuration of (C) Japanese Patent Publication No. 59-40037, since a sheet material cannot be used to prevent the above-mentioned stuffiness phenomenon, only the fabric is used for the skin layer, sewing machine sewing or high frequency Although the bag-shaped skin layer is formed by bonding by heating, it is necessary to set the foam and the skin layer in a stable state, and in the seating portion, the woven fabric and the foam are fitted in the uneven portion. It is configured to be adhesively bonded.

Therefore, not only the manufacturing process is very complicated and the cost is high, but also the direct bonding between the woven fabric and the foam cannot obtain a strong adhesion. Therefore, if enough adhesive is used to obtain a strong bond, the texture of the fabric may be impaired and contaminated, and the commercial value may be significantly impaired in practical use. Further, when the woven fabric and the foam are in direct contact with each other, the stress is not dispersed, and the seating stress is locally supported by the deformation of the foam, which promotes the reduction in the durability of the foam's impact resilience. It Further, the repeated cushioning may cause the woven fabric and the foam to be in an uneven state and to be in a free state, the foam is easily damaged, and the suitable seating feeling is also deteriorated, which is unsuitable for applications in which continuous use is intense. However, there is a problem that the durability is significantly reduced.

[Means for solving problems]

In the seat cushion structure of the above-mentioned conventional technology, it is necessary to solve the problem of stuffiness at the time of sitting, avoid the direct contact structure between the fabric and the foam, obtain durability and a suitable seating feeling and simplify the manufacturing process. is there.

Therefore, in the present invention, in order to solve the conventional problems,
Fabrics such as woven and knitted fabrics are used as the surface material, and a non-porous moisture permeable film with a moisture permeability of 1500 g / m ² · 24 hr. Or more is lined to form a skin layer to prevent stuffiness. In addition to the prevention, the manufacturing process is simplified by forming the bag-like shape by vacuum forming regardless of complicated processes such as sewing or welding.

That is, the moisture-permeable sheet cushion of the present invention is a moisture-permeable outer layer that is lined with a non-porous moisture-permeable film having a moisture permeability of 1500 g / m ² · 24 hr. It is characterized in that it is composed of a molded article having a shape and a foamed plastic which is filled in the bag-shaped inside of the molded article and bonded and integrated.

The method of manufacturing this moisture permeable sheet cushion is a moisture permeable outer layer formed by laminating and lining a non-porous moisture permeable film with a moisture permeability of 1500 g / m ² · 24 hr. A moisture-permeable sheet cushion is formed by vacuum suction with a vacuum forming die to form a bag-shaped outer casing molded body, and by injecting a foamed plastic composition liquid into the outer casing molded body and foam-filling and integrating them. Manufacture or
In the same manner as described above, a bag-shaped outer casing molded body is formed, and a foam molding member in which a plastic foam body having a required shape is molded by another molding die is attached to the inner surface of the upper die of the vacuum molding die. An adhesive is applied to at least one of the outer cover molded body and the foamed molded member, and then the upper mold is closed, and the outer cover molded body and the foamed molded member are pressure-bonded and integrated with each other. A wet seat cushion is manufactured.

It is a matter of course that the thickness of the moisture-permeable film needs to be maintained at a thickness that allows vacuum forming, but it can be determined according to the configuration and application of the seat cushion, and the thickness is limited. Not usually but currently 10
Used in the range of ~ 50μ. An example of the relationship between the film thickness (mm) and the water vapor transmission rate (g / m ² · 24 hr.) Is shown in the relationship graph (FIG. 8) between the film thickness and the water vapor transmission rate.

Since the adhesive used in the above-mentioned manufacturing method preferably has a moisture permeability similar to that of the moisture-permeable film, it is possible to form a non-porous adhesive layer having a moisture permeability of 1500 g / m ² · 24 hr. Or more. Although it is based on an adhesive, other adhesives can be used in the case of point-adhesion or line-adhesion.

Note that a detailed manufacturing method will be described in detail in Examples with reference to the illustrated drawings.

[Action]

The seat cushion of the present invention has a structure in which a fabric is used as a surface material, and a plastic foam is applied to a bag-shaped outer casing molded body having a required shape in which a fabric layer is formed by backing the fabric with an excellent moisture-permeable film. Due to the combined structure, it has excellent moisture permeability, there is no stuffy phenomenon when sitting for a long time, and the moisture permeability of the adhesive material does not impair the moisture permeability even if it is fully adhered, and the fabric and moisture permeability The adhesion with the film does not impair the texture of the fabric because a supporting adhesive that is practically suitable can be obtained without using much like the adhesion with the foam, and the fabric has elasticity and moisture permeability. Cushion stress is appropriately dispersed in the film because it is connected and supported by the film and connected to the foam, and the durability of the impact resilience of the foam and a suitable seat cushion Use can be obtained.

Further, in the manufacturing method, the outer layer using the fabric does not require a step such as sewing or welding, and is easily formed into a desired shape by vacuum forming, so that the manufacturing step is simplified.

〔Example〕

 Example-1 FIG. 1 is a partial sectional view of a moisture-permeable outer layer.

In the figure, reference numeral 1 denotes a moisture-permeable outer layer, which has a constitution in which a non-porous moisture-permeable film is lined on a surface material, and a surface material 2 of a fabric, a moisture-permeable adhesive 3, and a moisture-permeable film 4
The fabric surface material is a spandex tricot SE00 made by Kawashima Textile.
3 was used. In this case, the moisture-permeable adhesive was applied on the entire surface, and the thickness of the adhesive layer was 15 to 20 μm.

2 to 5 are sectional views for explaining the procedure for forming the seat cushion.

FIG. 2 is a cross-sectional view showing an outline of a vacuum forming die having a moisture-permeable outer layer setting. The moisture-permeable outer layer 1 is provided on the upper surface of the vacuum forming die 6 connected to a vacuum pump (not shown). It is set by the fixing jig 5. The temperature of this vacuum mold 6 is 60 °
The temperature is set within a range of ± 3 ° C (the mold temperature is appropriately selected depending on various materials used, and is usually 100 ° C or less), the moisture-permeable outer layer 1 is sucked, and the vacuum forming mold of FIG. As shown in the cross section, the outer casing molded body 1 (VCF) is formed. Next, the bag-shaped outer casing molded body 1 (VCF) formed in the vacuum molding die.
As shown in FIG. 4, the expandable plastic composition liquid is injected from the nozzle 7. In this example, a polyurethane foaming compounding liquid is used, the liquid temperature is kept in the range of 23 ° ± 2 ° C., and after injection, the upper mold 8 is closed as shown in FIG. To form an injection foam molding portion 9 and integrate it with the outer casing molded body 1 (VCF) to manufacture a moisture permeable seat cushion. The liquid temperature is not limited to the above temperature, but is usually room temperature.

Example 2 In this example, instead of injecting and foaming into a bag-shaped jacket molded body, a foam molded member 10 in which a plastic foam body having a desired shape is molded in advance with another molding die is used.

That is, in the same manner as in Example 1, the outer casing molded body 1 (VCF)
6 is formed in advance, and as shown in FIG.
Is attached to the inner surface of the upper mold 11 of the vacuum forming mold 6 and the moisture-permeable adhesive 3 is applied, and then the upper mold 11 is closed as shown in FIG. 7 to form the outer cover molded body 1 (VCF) and foam molding. The member (10) is pressure-bonded and integrated to manufacture a moisture-permeable sheet cushion.

The moisture permeable film 4 used for the moisture permeable sheet cushion may have various compositions. One example of the moisture permeable film used in the above examples is Japanese Patent Application No. 59-129542. It has the following composition presented in the issue.

That is, a polyethylene glycol having a molecular weight of 200 to 600 and an organic dicarboxylic acid alone or a mixture of a dicarboxylic acid and ε-caprolactone and / or a short chain polyol are reacted to give a polyoxyethylene content of 17 to 70% and a molecular weight of 50.
0 to 3000 polyester polyol, the polyester polyol is reacted with an organic polyisocyanate in the presence of a chain extender to give a polyoxyethylene content of 15 to
The moisture vapor transmission rate from the group of 62% polyurethane polymers
A film of 3207 g / m ² · 24 hr. Per 45 microns was selected and used, but regardless of thickness, it means that the water vapor permeability is essential.
It uses a moisture-permeable polyurethane film of 3207 g / m ² · 24 hr. However, if a film having the same material and a thickness of 20 μm is used, it is possible to obtain a high water vapor transmission rate of about 1.5 times from the relationship graph between the film thickness and the water vapor transmission rate.

Next, the moisture permeability of the seat cushion according to the manufacturing method of Example-1 and Example-2 was measured. The results are shown in Table 1.

As the composition of Example-1, fabric + moisture-permeable adhesive + moisture-permeable film + polyurethane foam (with a thickness of 1.5 m
Sheet sample No. 1 of (processed to m) was prepared, and as the composition of Example-2, fabric + moisture-permeable adhesive + moisture-permeable film + moisture-permeable adhesive + polyurethane foam (thickness: 1.5 mm
Processed sheet sample No. 2 is prepared, and the moisture permeability is JIS Z-020.
The results measured according to the method of 8 are shown. The moisture permeable film used was 3207 g / m ² · 24 hr./45μ.

As shown in Table 1 above, the seat cushion of the present invention has excellent moisture permeability.

The moisture-permeable adhesive used in Examples 1 and 2 is a moisture-permeable adhesive mainly composed of the same polyurethane polymer as the above-mentioned film, and has a molecular weight of 1800 for the film composition and a polyester polyol having a polyoxyethylene content of 60%. By reacting 1.9 mol of xylylene diisocyanate per mol to form a prepolymer having an isocyanate group at the terminal, methyl ethyl ketone was added to this so that the solid content was 50%, and then 1 mol of neopentyl glycol was added. Prepare a polyurethane polymer stock solution, and prepare this stock solution 100
10 parts of methoxymethylolated melamine and 5 parts of an amine-based curing agent are added per part to form a basic composition liquid of a moisture permeable adhesive. This basic composition liquid contains a softening agent (for example, Sumitex Softener) as needed for practical use.
S100, Sumitex Silicone Softener 10 and other plasticizers), weathering agents (for example, various anti-aging agents) pigments and other compounding agents are appropriately added.

Methyl ethyl ketone was used as a diluent in the above basic composition liquid to prepare an adhesive compounding liquid having a solid content of 25%. The adhesive film obtained from this adhesive compounding liquid by the casting method (casting) has a tensile strength of 203 kg / cm.
² , elongation 194%, moisture permeability 3800g / m ² · 24hr. / 20μ, water absorption swelling rate 0%.

This water absorption swelling rate, forming a film of thickness 20μ × width 30mm × length 150mm, put a marked line of 100mm interval to this film, then immersed in water at room temperature for 24 hours and then taken out from water, immediately after that The distance 1 between the marked lines is measured, and the water absorption swelling rate% is calculated.

For the application of the moisture-permeable adhesive, full-surface adhesion is usually adopted in order to maintain a sufficient adhesive force and ease of construction, but the thickness of the adhesive is usually 50 μm or less.

〔The invention's effect〕

The moisture-permeable seat cushion of the present invention has an excellent function as mentioned in the above action section,
The seat cushion has a characteristic that it can be obtained by a simple method without causing a stuffy phenomenon, durability and a comfortable sitting feeling for a long time.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view of a moisture-permeable outer layer, FIGS. 2 to 7 are explanatory cross-sectional views showing a forming procedure of a seat cushion, and FIG. 8 is a relation graph between film thickness and moisture permeability. Is. 1 ... Moisture-permeable outer layer, 2 ... Surface material of fabric 3 ... Moisture-permeable adhesive, 4 ... Moisture-permeable film 1 (VCF) ... Outer-molding body 6 ... Vacuum forming mold, 9 ... Injection foam molding part 10 …… Foam molding member, 11 …… Upper mold

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B29K 105: 04 B29L 31:58 (56) References JP-A-54-40872 (JP, A)

Claims (4)

[Claims] 1. A fabric as a surface material has a moisture vapor transmission rate of 1500.
An outer cover molded body having a bag-shaped required shape, which is a moisture-permeable outer layer backed by a non-porous moisture-permeable film of g / m ² · 24 hr. or more, and a bag-shaped inside of the outer cover molded body. A breathable seat cushion, which is composed of a foamed plastic which is filled and bonded and integrated. 2. A fabric as a surface material has a moisture vapor transmission rate of 1500.
A non-porous moisture-permeable film of g / m ² · 24 hr. or more is laminated and lined with an adhesive, and the moisture-permeable outer layer is vacuum-sucked by a vacuum molding die to form a bag-shaped outer casing. A method for producing a moisture-permeable sheet cushion, which comprises forming a molded body into a body, injecting a foamed plastic composition liquid into the molded body to foam-fill and integrate the body. 3. A fabric as a surface material has a moisture vapor transmission rate of 1500.
A non-porous moisture-permeable film of g / m ² · 24 hr. or more is laminated and lined with an adhesive, and the moisture-permeable outer layer is vacuum-sucked by a vacuum molding die to form a bag-shaped outer casing. A body is formed, and a foam molding member in which a plastic foam having a desired shape is molded in advance with another molding mold is attached to the inner surface of the upper mold of the vacuum molding mold, and at least one of the jacket molding body and the foam molding member is attached. A method for producing a moisture-permeable sheet cushion, which comprises applying an adhesive to, and then closing the upper mold, and pressure-bonding the outer cover molded body and the foamed molded member to integrate them. 4. The adhesive according to claim ² , wherein the adhesive is a moisture permeable adhesive capable of forming a non-porous adhesive layer having a moisture permeability of 1500 g / m ² · 24 hr. Or more. Method for manufacturing a breathable seat cushion.