JPH09327878A - Laminate for vehicle sheet and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a laminate for a vehicle sheet excellent in a soft feeling, a touch, and productivity while a specific peel strength is provided by a method wherein a fiber web layer and a pad layer are integrated by laminating with bond in an innumerable spotty bond parts made to lie between the fiber web layer and the pad layer. SOLUTION: A fiber web layer and a pad layer are integrated by laminating by bond in an innumerable spotty bond parts made to lie between them. An inserted distance of a fiber filament bundle 3 into the pad layer 2 is about 5-8mm to a 10mm thickness of the pad layer 2, and prevention of needle breakage in sewing and smoothening of a surface property of the fiber web layer 1 are achieved. When a thickness of the pad layer 2 is comparatively thin, for example, 5mm or thinner, the fiber filament bundle 3 is protruded from a rear face side, and its tip part is expanded in a loop form or radially. If made as abovementioned, its peel strength can be made more larger.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention has a soft feeling,
The present invention also relates to a laminated material for vehicle seats having excellent peel strength and a method for manufacturing the same.

[0002]

2. Description of the Related Art A laminate for a vehicle seat in which a fibrous web layer made of a non-woven wadding material and a pad layer made of a synthetic resin foam such as slab urethane are integrated is disclosed in, for example, Japanese Utility Model Publication No. 3-84133. As described above, by inserting the fiber of the wadding material into the slab urethane by needle stick processing, the two are integrated,
As disclosed in Japanese Patent No. 87242, a hot melt film interposed between the two is melted by steam and made to act as an adhesive to be bonded and integrated, and the like.

However, in consideration of mounting on a seat assembly, a peel strength of 0.3 kg / 25 mm width or more is usually required as the material strength, and in the former case, it is so-called to secure this strength only by needle stick processing. It is necessary to increase the number of penes and depth considerably, but this will greatly reduce the softness and texture,
There is a problem that it is actually difficult to secure the above peel strength only by needle stick processing while maintaining the texture as a sheet material. On the other hand, in the latter case, depending on the selection of the wadding material and the hot melt film, and the adjustment of the number of penes and the depth, it is theoretically possible to obtain the desired peel strength, softness and texture of the sheet material. However, there are problems that it is difficult and complicated to set various conditions, and the manufacturing process is complicated and diversified, resulting in poor productivity and high cost.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and has a predetermined peel strength required as a sheet material and is excellent in soft feeling and texture, and The present invention has been completed for the purpose of providing a laminated material for vehicle seats, which can be manufactured with a simple manufacturing process, excellent productivity and low cost, and a manufacturing method thereof.

[0005]

DISCLOSURE OF THE INVENTION The present invention, which has been made to solve the above-mentioned problems, provides a fiber web layer composed of innumerable fiber filaments and a pad layer composed of a synthetic resin foam laminated on the fiber web layer. Laminated and integrated by entanglement by a fiber filament bundle formed by needle sticking from the web layer side into the pad layer and adhesion at the innumerable point-like adhesive portions interposed between the fiber web layer and the pad layer A laminated material for vehicle seats, a fibrous web layer composed of innumerable fiber filaments, an adhesive web that melts by heating to exhibit adhesiveness, and a pad layer composed of a synthetic resin foam. Are sequentially stacked and needle-punching is performed from the fiber web layer side into the pad layer to form a primary laminate in which the fiber filament bundle is pierced into the pad layer, and the primary laminate has air permeability. A heating fluid is passed inside while being sandwiched and pressed by a holding member, heat setting treatment of the fiber filament by heating, and melting and agglomeration of the adhesive web that can be divided by needle stick processing, and cooling this And a fiber web layer and a pad layer are laminated and integrated by entanglement by the fiber filament bundle and adhesion at a myriad of dot-shaped adhesive portions. Is.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. In the figure, 1 is a unit weight of 3 innumerable fiber filaments such as polyester fibers.
0-500 g / m ² fibrous web layer, 2 has a density of 0.02
A pad layer made of synthetic resin foam such as slab urethane of g / cm ³ (10 mm thickness), both of which were formed by stacking and needle-punching the fiber web layer 1 side into the pad layer 2. The entanglement by the fiber filament bundle 3 and the adhesion at the dot-shaped adhesive portion 4 interposed between the fiber web layer 1 and the pad layer 2 are laminated and integrated.

As described above, the fibrous web layer 1 and the pad layer 2 are integrated by only entanglement by a conventional needle sticking process, or only by an adhesive layer interposed therebetween. Different from the above, the combined use of the entanglement by the fiber filament bundle 3 formed by the needle sticking process as described above and the adhesion in the dot-shaped adhesive portion 4 interposed between the fiber web layer 1 and the pad layer 2 As a result, the needle stick processing can be performed with a relatively small number of penes, about 15 per cm ^2, and partial adhesion at the dot-shaped adhesive portion 4 is sufficient. There is a feature of.

That is, by suppressing the number of penes for needle stick processing to be low, it is possible to prevent the fibrous web layer 1 from tightening and becoming hard, to secure an appropriate soft feeling and texture, and to bond the fibrous web layer 1 through the dot-shaped adhesive portions 4. As a result, a sufficient adhesive strength with the pad layer 2 can be secured, and a soft texture of the pad layer can be maintained as compared with the conventional full-face adhesion. In addition, as a method of forming the dot-shaped adhesive portion 4, as will be described later, the needle is used in a state in which an adhesive web that is melted by heating and exhibits adhesiveness is interposed between the fibrous web layer 1 and the pad layer 2. Puncture processing is performed, and the adhesive web is cut or perforated to such an extent that it can be cut by the fiber filament bundle 3 formed by the needle stick processing, and the adhesive web is heated and melted during the subsequent heat setting process. It is preferable to employ a method in which the dot-shaped adhesive portions 4 are formed by agglomerating in a dot shape and then cooled.

Reference numeral 5 denotes a backing cloth 5 which is attached to the pad layer 2 as needed and is integrated with the pad layer 2 by means such as a fiber filament bundle 3 formed by the above-mentioned needle stick process or an adhesive. , For example, a nonwoven fabric sheet made of polypropylene fiber, polyester fiber, polyamide fiber, etc., which has good abrasion resistance and is commercially available called spunbond, or a woven fabric sheet made of tricot fiber is laminated to obtain mechanical strength. By improving the height of the seat cover, it is possible to facilitate the sewing work of the seat cover and the work of covering the seat.

In FIG. 1, the insertion amount of the fiber filament bundle 3 into the pad layer 2 is set to about 5 to 8 mm with respect to the thickness of the pad layer 2 of 10 mm so as to prevent needle breakage during the needle sticking process and the fiber web. Although the surface texture of the layer 1 is intended to be smoothed, as shown in FIG. 2, when the thickness of the pad layer 2 is relatively thin as 5 mm or less, the fiber filament bundle 3 is projected from the back surface side. It is possible to further increase the peel strength by setting the tip end portion to be expanded in a loop shape or a radial shape.

Next, referring to FIG. 3, a method of manufacturing the above-mentioned laminated material for vehicle seats will be described. A fiber web layer 1 made of innumerable fiber filaments and a pad layer 2 made of synthetic resin foam are formed by an ordinary card machine. Is fed to the needle punching machine 7 with the adhesive web 6 interposed in the middle part. The adhesive web 6 is different from the conventional adhesive hot melt film and refers to a low-melting point fibrous web such as polyamide fiber or polyester fiber or a hot melt web (basis weight is 10 to 20 g / m ² ). In this way, a fibrous web layer 1 consisting of innumerable fibrous filaments
Then, the adhesive web 6 that melts by heating and exhibits adhesiveness, and the pad layer 2 made of a synthetic resin foam are sequentially stacked and sent to the needle punch machine 7, whereby the pad layer is formed from the fiber web layer 1 side. When needle stick processing is applied into 2,
The fiber filament bundle 3 is pierced into the pad layer 2 to form a primary laminated body, and then this primary laminated body is introduced into the heater 8. As the heating device 8, for example, a heating fluid such as hot air of 130 to 150 ° C. is passed through while sandwiching and pressurizing from both upper and lower surfaces with sandwiching members 9, 9 having air permeability such as punching metal, This heating machine 8
After passing through, the above-mentioned primary laminated body is heat-set in a state of being compressed to a predetermined thickness.
By this heat setting treatment, the adhesive web 6 in the above-described separable state is melted and aggregated mainly in the vicinity of the interface between the fiber filament bundle 3 and the pad layer 2 due to the surface tension, and is made into dots. After cooling, an infinite number of dot-shaped adhesive portions 4 are formed, and the fibrous web layer 1 and the pad layer 2 are bonded and integrated through the dot-shaped adhesive portions 4, after which they are continuously wound on a winder. It is considered as an item.

The laminated material for vehicle seats thus obtained can keep the number of penes for needle stick processing low, so that the fibrous web layer 1 does not become tight due to being tightened, and a suitable soft feeling and texture are obtained. In addition to the above, since the fibrous web layer 1 and the pad layer 2 are not only integrated by the entanglement in the filament bundle 3 by the needle sticking process described above, but also adhered via the dot-shaped adhesive portion 4, Unlike the above-described entire surface adhesion, a sufficient adhesive strength is secured while maintaining the soft texture of the pad layer 2. Also, the pad layer 2
Since the fiber filament bundle 3 inserted therein has a crosslinked structure to prevent the lateral displacement of the fiber web layer 1,
Even if the sheet is thicker than 5 mm, the lateral displacement of the seat when seated can be reliably prevented. Furthermore, since the processing temperature during the heat setting process can be relatively low at 130 to 150 ° C., no toxic gas is generated from the pad layer 2 and safety is excellent.

The peel strength of the laminated material for vehicle seats shown in FIGS. 1 and 2 is sufficiently higher than the practical strength (0.3 kg / 25 mm width) as shown in FIG. While it was confirmed (white circles A and B),
The peeling strength (black circle C) of the laminated material under the same conditions as the whole surface bonding instead of the dot-shaped bonding portion was equal to or less than the practical strength, and the excellent effect of the present invention was confirmed.

[0014]

As is apparent from the above description, the laminated material for a vehicle sheet according to the present invention has a predetermined peel strength required as a sheet material and is excellent in soft feeling and texture. In addition, the method for producing a laminated material for a vehicle seat according to the present invention is capable of efficiently producing the laminated material for a sheet in a simple production process and at a low cost. Therefore, the present invention, as a laminated material for a vehicle seat and a method for manufacturing the same for which the conventional problems have been eliminated, greatly contributes to industrial development.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a laminated material for vehicle seat according to the present invention.

FIG. 2 is a cross-sectional view showing another embodiment of the laminated material for vehicle seats according to the present invention.

FIG. 3 is a front view showing a manufacturing process of a method for manufacturing a laminated material for vehicle seats according to the present invention.

FIG. 4 is a graph showing the peel strength of the laminated material for vehicle seats according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber web layer 2 Pad layer 3 Fiber filament bundle 4 Point adhesive part 5 Back base cloth

Claims (3)

[Claims] 1. A fibrous web layer (1) made of innumerable fibrous filaments and a pad layer (2) made of synthetic resin foam laminated on the fibrous web layer (1) are arranged from the fibrous web layer (1) side to the pad layer.
(2) Entangling with the fiber filament bundle (3) formed by needle sticking into the inside, and the fiber web layer (1) and the pad layer
A laminated material for a vehicle seat, characterized in that it is laminated and integrated by the bonding in the innumerable spot-shaped adhesive portions (4) interposed between the laminated material and the (2). 2. The laminated material for vehicle seats according to claim 1, wherein the backing cloth (5) is laminated and integrated on the surface of the pad layer (2). 3. A pad comprising a fibrous web layer composed of innumerable fibrous filaments, an adhering web which melts by heating to exhibit an adhering ability, and a pad layer composed of a synthetic resin foam, which are laminated in this order from the fibrous web layer side. The layer is needle-pierced to form a primary layered body in which the fiber filament bundle is pierced into the pad layer.The primary layered body is sandwiched and pressed by a breathable sandwiching member while the heating fluid is passed inside. Then, heat setting treatment of the fiber filament by heating and melting and aggregating the adhesive web capable of being divided by needle stick processing, and cooling the fiber web layer and pad layer by the fiber filament bundle. A method of manufacturing a laminated material for a vehicle sheet, which comprises laminating and integrating by entanglement and adhesion at innumerable point-shaped adhesive portions.