JPH08224384A - Cushion material and its manufacture - Google Patents

Abstract

PURPOSE: To manufacture a cushion material for seat cushion, seat back, etc., at a low cost without deteriorating the working environment. CONSTITUTION: Thermo-plastic resin fibers 11 are used to a cushion core 19, which is bonded by heating and softening the fibers 11 and covered with a skin material 14 so that a cushion material is made. In manufacturing this cushion material, the fibers 11 are put fully in a die 21 in which the skin material 14 is inserted and are softened by heating with a hot air or water vapor so that the cushion material 19 is bonded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion material such as a seat back of a seat installed in an automobile or a seat cushion, and a method for producing the cushion material.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 7, partial molds (2, 3)
The surface material (4A) and the surface material (4A)
A skin material (4) consisting of a synthetic resin foam (4B) attached to the back surface of (A) and a non-woven fabric (4C) lined with the synthetic resin foam (4B), and a backing material (5) And then insert the liquid urethane molding material into the interior, and then foam and cure the urethane molding material to form a cushion core material (6) made of polyurethane foam. A cushioning material (7) comprising 6) and a skin material (4) covering the cushioning core material (6) is manufactured.

[0003]

In the conventional cushioning material (7) described above, since the liquid urethane molding material is injected into the mold of the molding die (1), the molding material is intercalated with the skin material (4). Masking tape (8), etc. must be attached so as not to leak outside from the seam of the skin and the seam of the skin material (4) and the lining material (5), and the non-woven fabric of the skin material (4). In order to prevent the molding material from invading the synthetic resin foam (4B) from (4C), it is necessary to apply synthetic resin or the like to the nonwoven fabric (4C) to carry out sealing. The sealing process is very troublesome, and the liquid urethane molding material has a problem that it has an odor and deteriorates the working environment.

[0004]

As a means for solving the above-mentioned conventional problems, the present invention provides a cushion core material (19),
The cushion core material (19) is covered with a skin material (14), the cushion core material (19) is a fiber material (11) using a thermoplastic synthetic resin fiber, and the cushion core material (19). Provides a cushion material (20) bound by heating and softening thermoplastic synthetic resin fibers, and the cushion core material (19) has a frame (20B) and / or
Alternatively, a fiber mat (19B) may be interpolated. As a method for producing the cushion material (20), the skin material (14) is inserted into the molding die (21), and a fiber material using a thermoplastic synthetic resin fiber in the skin material (14) (11 ) Of the cushion core material (19), and hot air or steam is introduced into the mold (21) to heat the cushion core material (19), and heat contained in the cushion core material (19). A method of binding the cushion core material (19) by heating and softening the plastic synthetic resin fiber and bonding the cushion core material (19) and the skin material (14) is applied, and if desired, the molding die A frame (20B) and / or a fiber mat (19B) may be inserted in the (21).

In the present invention, the cushion core material is composed of thermoplastic synthetic resin fibers or a mixed fiber of thermoplastic synthetic resin fibers and other fibers. The thermoplastic synthetic resin fibers are, for example, polyethylene fibers, polypropylene fibers, low melting point polyester fibers having a melting point of 200 ° C. or lower, low melting point polyamide fibers having a melting point of 200 ° C. or lower, and as shown in FIG. Other fibers such as polyester fibers, polyamide fibers, acrylic fibers, acetate fibers, and cotton fibers having a melting point of 200 ° C. or higher are used as the core part (12), and the core part (12)
Alternatively, a thermoplastic composite fiber (11) coated with the sheath portion (13) made of the above-mentioned thermoplastic synthetic resin fiber may be used. From the viewpoint of reuse, in the composite fiber (11), the core part (12) and the sheath part (13) are the same kind of synthetic resin, for example, the core part (12) is 250
Polyester having a melting point of ℃ or more, the sheath (13) is 200
A composite fiber made of polyester with a melting point of ℃ or less (1
1) is desirable. In order to give the cushion core material good elasticity, the thermoplastic synthetic resin fiber (11) is waving-treated as shown in FIG. 2, or has a thermal crimping property that is crimped by heat during molding. Is desirable.

In the cushion material of the present invention, the above-mentioned thermoplastic synthetic resin fibers and other fibers, for example, synthetic fibers such as polyester fibers, polyamide fibers, acrylic fibers, acetate fibers having a melting point of 200 ° C. or higher, cotton fibers, bamboo fibers, A mixed fiber of natural fibers such as hemp fiber and coconut fiber may be used. In this case, it is desirable that the thermoplastic synthetic resin fiber is contained in the mixed fiber in an amount of 40% by weight or more.

In the present invention, as the skin material for covering the cushion core material, artificial leather such as polyvinyl chloride leather, polyurethane leather, polyamide leather or the like, non-woven fabric or knitted fabric such as polypropylene fiber, polyester fiber, polyamide fiber or acrylic fiber is used. Alternatively, a fiber material such as the non-woven fabric or a raised fabric of knitted fabric is used, but as a preferable skin material, the above material is used as a surface material (15) and a backing material (16) is lined on the back surface as shown in FIG. In some cases, the back surface of the wadding material (16) is lined with a non-woven fabric (17). As the wadding material (16), polyester fiber, polypropylene fiber, polyamide fiber,
Thick non-woven fabrics (usually 1 to 10 mm) of synthetic fibers such as acrylic fibers and cotton fibers, and natural fibers, synthetic resin foams such as polyurethane foam, polyethylene foam, polypropylene foam, polyvinyl chloride foam, etc. are used. Non-woven fabric (17)
As the non-woven fabric used as the wadding material (16), a thin one is used.

A fiber mat for providing rigidity may be inserted into the cushion core material. As the fiber mat, a fiber material containing thermoplastic synthetic resin fibers similar to the cushion core material is used, but the density is increased to 0.2 to 0.5 g / cm ^3, and if desired, the fiber mat was formed into a predetermined shape. It may be one.

In the present invention, the cushion core material, the skin material, and the fiber mat are the same synthetic resin material for reuse.
For example, it is desirable to use polyester, polypropylene or the like. If the same synthetic resin material is used in this manner, scrap can be easily melted and used as it is, or pelletized and reused as a material such as a fiber or a molded product.

[0010]

In the present invention, since the thermoplastic synthetic resin fiber having thermal binding property is used as the material of the cushion core material, there is no possibility that the material of the cushion core material leaks from the skin materials or the joint between the skin material and the lining material. . Therefore, the masking process is unnecessary. The material of the cushion core material of the present invention is of course odorless and non-toxic, and does not deteriorate the working environment.

[0011]

【Example】

Example 1 This example is shown in FIGS. 4 and 5. The molding die (2
1) consists of partial molds (22, 23), and the partial mold (22) has a built-in steam or hot air introduction path (24) that opens to the mold surface.
Further, the partial mold (23) has a built-in suction passage (25) which opens to the mold surface. The skin material (14) and the lining material (18) are inserted into the molding die (21) and set in a closed state, and then the material fiber (11) of the cushion core material is pressed into the molding die (21). Fill by air or inhalation. The skin material (14) has, for example, a polyester fiber knitted fabric as a surface material (15), and a thick non-woven fabric of polyester fiber (thickness 5 mm) as a wadding material (1).
6), which is lined with a thin nonwoven fabric (17) of polyester fiber, and the material fiber (11) of the cushion core material uses a polyester fiber having a melting point of 250 ° C. for the core part (12) and a sheath part ( 13) is a heat-crimpable fiber that uses a polyester resin having a melting point of 150 ° C., and the lining material (18) is a polyester fiber gauze, and the skin material (14) is mutually or skin material (14).
And the seam (14A) of the lining material (18) is sewn with polyester thread.

From the partial mold (22) of the molding mold (21), an introduction path is introduced.
Hot air or steam of 180 ° C. is blown into the molding die (21) through the (24), and the material fiber (11) of the cushion core material
Is heated, the hot air is sucked into the suction path (25) of the partial mold (23),
It is heated and circulated again to the introduction path (24) of the partial mold (22).

By the above heating, the material fibers (11) of the cushion core material are softened and crimped and fused together, and also fused with the nonwoven fabric (17) of the skin material (14) and the backing material (18). In this way, a cushion core material having good cushioning properties (19)
After that, cold air is blown into the molding die (21) from the introduction path (24) of the partial die (22) to cool the inside. In this way, a seat cushion (20) as shown in FIG. 5 is manufactured, and the cushion (20) is taken out from the molding die (21).

Example 2 A molding die (21A) used in this example is shown in FIG. There is an introduction path (2) between the partial mold (22A) and the partial mold (23A) of the mold (21A).
4A) and suction channel (25A) are built in respectively. The skin material (14A) used in the present example is made of polypropylene fiber knitted fabric as the surface material (15A), polypropylene foam as the wadding material (16A), and the non-woven fabric is not lined. A waving-treated polypropylene fiber is used as the material fiber (11A) of the cushion core material, and a polypropylene nonwoven fabric is used as the backing material (18A). In this embodiment, a fiber mat (19B) and a frame (20B) provided with an S spring (20C) are inserted in a molding die (21A), and then the material fibers (11A) are filled, and hot air or steam at 170 ° C. Example 1
Heat molding is performed in the same manner as. As the fiber mat (19B), a polypropylene non-woven fabric molded product having a thickness of 5 mm and a basis weight of 1000 g / m ² is used. Thus, the seat cushion (20A) as shown in FIG. 5 is manufactured.

[0015]

Therefore, in the present invention, a cushioning material such as a seat cushion or a seat back can be manufactured by omitting a masking material and a masking treatment step and maintaining a good working environment.

[Brief description of drawings]

FIG. 1 is a partial perspective view of a composite fiber.

FIG. 2 Partial side view of fiber

FIG. 3 is a partial side view of a skin material. FIGS. 4 and 5 show Embodiment 1 of the present invention.

FIG. 4 is a sectional view of a molded state

FIG. 5 is a perspective view of a seat cushion

FIG. 6 is a sectional view of a molded state of Example 2

FIG. 7 is a sectional view of a conventional molding state.

[Explanation of symbols]

 1,11A Material fiber 14,14A Skin material 19,19A Cushion core material 19B Fiber mat 20B Frame 21,21A Mold 24,24A Hot air or steam introduction path 25,25A Suction path

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Claims (4)

[Claims] 1. A cushion core material and a skin material covering the cushion core material, the cushion core material being a fiber material using a thermoplastic synthetic resin fiber, and the cushion core material being a thermoplastic synthetic resin. Cushion material characterized by being bound by heating and softening fibers 2. The cushion material according to claim 1, wherein a frame and / or a fiber mat is inserted in the cushion core material. 3. A method of manufacturing a cushion material comprising a cushion core material and a skin material covering the cushion core material, comprising inserting the skin material into a molding die, and further heat-treating the skin material. A thermoplastic synthetic resin fiber contained in the cushion core material is filled with a cushion core material made of a fiber material using a plastic synthetic resin fiber, and hot air or steam is introduced into the mold to heat the cushion core material. A method for producing a cushioning material, characterized in that the cushioning material is softened by heating to bond the cushioning material, and the cushioning material and the skin material are adhered to each other. 4. The method for producing a cushioning material according to claim 1, wherein a skin material and a frame and / or a fiber mat are further inserted in the molding die.