JPH10127431A - Manufacture of seat cover - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to manufacture a product free from flattened or whitened fibers when a skin material is made to adhere to a fiber web layer by overlaying the skin material on the web layer surface through an intervening adhesion layer by carrying out the adhesion of the skin material while pressing and smoothing the surfaces of the adhesion layer and the web layer in a molten state. SOLUTION: When a material to be processed comes in with an adhesion layer 3 and a backing sheet 4 overlaid respectively on top and reverse surfaces of a fiber web layer 1, the adhesion layer 3, the web layer 1, and the backing sheet 4 are made into a laminate body using a needle punching machine 10. Next, a skin material 2 is overlaid on the adhesion layer 3 and they are brought into a heat setting chamber 11 where the adhesion layer 3 is melted to cause the skin material 2 to adhere to the web layer 1. Here, in the heat setting chamber 11, hot air is supplied in the direction from the top side of the skin material 2 to the reverse side of the web layer 1 to melt only the adhesion layer 3 and a filament of a low melting point fiber. Adhesion of the skin material 2 is done while flattening and smoothing the web layer 1 surface and the adhesion layer 3 by pressing with a pressure plate 12 in a cooling zone 11b.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a material for a skin material which does not fall down even if it is made of a material which is easily affected by heat pressure during heat setting, such as a fabric having a raised material.
The present invention relates to a method for manufacturing a seat cover that can easily mass-produce a sheet of an automobile or the like having an excellent appearance quality by being able to accurately and easily adhere the skin material to the fibrous web without causing unevenness of the fiber web layer and the adhesive layer to appear on the skin material. It is.

[0002]

2. Description of the Related Art Conventionally, as a seat cover used for a seat of an automobile or the like, a laminated skin material in which a skin material is integrally attached to a surface of a plastic foam such as a polyurethane foam has been often used. Foams are costly and have problems of disposal pollution or recycling. Recently, a fiber web layer in which long fibers such as polyester fibers are entangled is used as a wadding material, and the skin is applied via an adhesive layer. A material in which materials are integrally bonded has been proposed (for example, Japanese Utility Model Application Laid-Open No.
15899 and JP-A-4-332590).

When manufacturing such a seat cover,
Conventionally, the fiber web layer, the adhesive layer, and the skin material are superimposed and compressed to a predetermined thickness by a plate-like pressing member having air permeability, and hot air is passed through to perform bonding and heat setting. However, when the bonding and heat setting are performed in this manner, the pressing member heated to a high temperature by hot air directly presses the skin material, so that the surface of the skin material is thermally affected, particularly In addition, when the skin material is a fabric having a raised material, there is a problem that the appearance quality is remarkably impaired such that the raised material falls down or a whitening phenomenon occurs.

[0004]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned conventional problems, and has an appearance quality in which the surface of the skin material is not affected by heat during heat setting processing, and there is no hair falling or whitening. The purpose of the present invention is to provide a method of manufacturing a seat cover capable of producing an excellent product, and exhibiting excellent productivity and efficiently performing mass production at low cost. .

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, a method for manufacturing a seat cover according to the present invention is characterized in that a hot-melt adhesive is applied to the surface of a fibrous web layer at least partially using low-melting fibers. A method of manufacturing a seat cover in which an air-permeable skin material is laminated through a layer, and the adhesive layer is melted by passing hot air to bond the skin material to the fiber web layer and heat-set the fiber web layer. In the method, hot air is supplied from the front side of the skin material to the back side of the fiber web layer without positively pressing the fiber web layer and the skin material, and the low melting point fiber of the fiber web layer is bonded to the heat-meltable material. Immediately after the layers are melted, they are cooled while being actively pressurized by a pressurizing plate, and the surface material is adhered to the surface of the fibrous web layer in a molten state and the adhesive layer while being pressure-smoothed. It is characterized in that compressing the fiber web layer to a predetermined thickness.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to a manufacturing process explanatory diagram shown in FIG. 1 and a sectional view of a seat cover obtained by the present invention shown in FIG. explain. In the figure, 1 is a fibrous web layer made of a mixed fiber of a filament 1a of a high melting point fiber and a filament 1b of a low melting point fiber, 2 is a breathable skin material excellent in heat resistance, 3 is a thin web of a low melting point fiber or The adhesive layer 4 that is melted when heated to about the melting point of the low-melting fiber such as a hot melt web to give an adhesive ability, and 4 is a backing base fabric that is stacked on the back surface of the fiber web layer 1 as necessary. . The mixing ratio of the filament 1a of the high melting point fiber and the filament 1b of the low melting point fiber in the fiber web layer 1 composed of the mixed fiber is usually about 7: 3 to 9: 1. Normally about 100 to 500 g / m ² .

A fibrous web layer 1 comprising the above-mentioned mixed fiber
As the high-melting fiber filament 1a, for example, a polypropylene-based fiber, a polyester-based fiber, a polyamide-based fiber or the like having a melting point of 160 to 240 ° C. and about 2 to 13 denier is used. As the filament 1b, for example, the melting point of polyester fiber or polypropylene fiber is 100 to 160 ° C.
About 2 to 6 denier is used. The filament 1b of the low-melting fiber is not entirely low-melting, but has a low-melting point such as polyester resin or polypropylene resin having a melting point of 100 to 160 ° C. on the surface of a core material made of a polyester or other resin having a relatively high melting point. Core-sheath fibers coated with the above resin can also be used.

On the other hand, the present invention is extremely effective when the skin material 2 has a relatively high melting point, a breathability and a raised surface on the surface, such as a fabric material made of polyester fiber. . As the adhesive layer 3, a thin web made of filaments of a low melting point fiber of a total fusion type having a melting point of 100 to 160 ° C., a basis weight of about 10 to 50 g / m ² and about ² to 6 denier, or a certain amount of ventilation Sheet type hot melt web etc. having properties are used,
Furthermore, the backing base cloth 4 is made of a high-density nonwoven fabric structure generally called a spunbond cloth, and is used for the purpose of improving the strength of the seat cover as required.

In FIG. 1, reference numeral 10 denotes a needle punching machine for performing needle sticking on the fiber web layer 1 described above;
11 is a heat set room, and this heat set room 11
The heating zone 11a and the cooling zone 11b are formed continuously, and a belt conveyor 13 for conveyance using a gas-permeable mesh material such as a mesh wire as a conveyor belt is installed therein so as to pass through each zone. The belt conveyor 13 is provided inside the cooling zone 11b.
The pressure plate 12 is provided on the upper side corresponding to the above. The pressing plate 12 is for compressing the fibrous web layer to a predetermined thickness while performing a cooling process.In the illustrated example, the pressing plate 12 is a belt conveyor made of a metal plate conveyor belt such as a stainless steel plate. The material to be processed, which is passed by pressure members 14 and 15 such as a pair of upper and lower pressure rollers provided inside, is sandwiched between the pressure plate 12 and the belt conveyor 13 and is pressed. The pressure plate 12 can be made of a gas-permeable mesh material such as a mesh wire mesh, similarly to the belt conveyor 13, and can be a simple plate-shaped pressure member instead of the belt conveyor. The pressure plate 12 is adjusted to a temperature of 30 ° C. or lower by a general cooling means such as a fan (not shown) that sends cold air of about 10 to 30 ° C. into the cooling zone 11b. Pressure compression while cooling.

Next, the molding process of the seat cover of the present invention will be described with reference to FIG. First, when the material to be processed is sent to the line in a state where the adhesive layer 3 and the backing base fabric 4 are superimposed on the front and back of the fiber web layer 1, the number of penetrations is reduced by the needle punch machine 10 according to a conventional method. A few dozen needle stings are performed, whereby the adhesive layer 3, the fiber web layer 1, and the backing fabric 4 are entangled and integrated into a laminated body. And the skin material 2 is fed into the heat setting chamber 11, where the adhesive layer 3 is melted and the skin material 2 is bonded to the fibrous web layer 1 and heat set to be sent out as a product. Is basically the same as a conventional method of manufacturing this type of seat cover, but the present invention has a feature in the bonding in the heat setting chamber 11 and the heat setting process.

That is, the heating zone 1 of the heat set chamber 11
When the material to be processed is sent to the heat setting chamber 11a, the filament 1a of the high melting point fiber
Filament 1b of low melting point fiber having a melting point lower than
Hot air having a melting point of at least about 120 to 180 ° C. is supplied from the front side of the skin material 2 to the back side of the fibrous web layer 1. 3 was melted, the surface of the melted low-melting fiber filament 1b that could be bonded at the contact point with the high-melting fiber filament 1a was in a molten state, and the fibrous web layer 1 and the skin material 2 were melted. The adhesive layer 3 is ready for adhesion. In this case, even if only the wind pressure due to the supply of hot air having a wind speed of about 0.5 to 3 m / s acts on the skin material 2, it is not intentionally pressurized by the pressurizing member. There is no occurrence of a phenomenon in which hair is fallen by being pressed by the pressing member.

Next, when the material to be processed is sent to the cooling zone 11b of the heat setting chamber 11 in a state where the filament 1b of the low melting point fiber and the adhesive layer 3 are melted as described above, the cooling zone 11b Is positively pressed by the pressure plate 12 whose temperature is adjusted to 30 ° C. or less. When the positive pressure is applied by the pressing plate 12 immediately after the low-melting fiber filament 1b and the adhesive layer 3 are sent to the cooling zone 11b in a molten state, the pressing by the pressing plate 12 Cooling is performed while the compression pressure is dispersed throughout, but the pressing force is transmitted via the skin material 2 between the surface of the fibrous web layer 1 and the adhesive layer 3 which are in a molten state in the initial stage of cooling, and the surface is smoothed. The skin material 2 is adhered while being cooled, and at the same time, the fiber web layer is compressed to a predetermined thickness while being cooled while the compression pressure is dispersed throughout the fiber web layer. Then, when the cooling proceeds to 70 to 90 ° C., which is the softening point of the low-melting fiber filament 1 b and the adhesive layer 3, the low-melting fiber filament 1 b melted earlier becomes the high-melting fiber filament 1 a in contact therewith. We fuse. When a core-sheath fiber filament is used as the low-melting fiber filament 1b, only the sheath portion is fused and the core portion is not affected at all by the heat, so that the fiber web layer 1 having higher strength is obtained. It is particularly preferable because it can be performed.

[0013] When the cooling zone 11b finally cools down to a temperature range of 10 to 30 ° C, the softened low-melting fiber filament 1b and the adhesive layer 3 are both completely cooled, and the adhesive force is reduced. While being reinforced, the mixed fiber web 1 is compressed to a predetermined thickness by being sandwiched between the conveyor belts by the action of the pressing members 14 and 15, and is set in this compressed state. Will be held. During this pressing, the surface of the skin material 2 is
2 but pressurized at a low temperature of 30 ° C. or less, so that the hair material of the skin material 2 does not cause the hair falling phenomenon and the skin material 2 does not cause the whitening phenomenon, and the appearance quality is improved. An excellent product can be produced, and the pressure is applied in a state where the compression pressure is dispersed by the pressing plate 12, so that the adhesive strength is uniform, and the skin material 2 is smoothed by pressing in the molten state. Is bonded to the fibrous web 1 which has been formed via the smoothed adhesive layer 3.
Even with a thin skin material, a high quality product with a smooth surface can be obtained without being affected by the unevenness of the fibrous web 1.

[0014]

As is apparent from the above description, the present invention does not cause the skin material to fall down or whiten under the influence of heat due to the pressure during heat setting, and also has a fiber web on the surface. Since there is no unevenness of the layer or the adhesive layer, it is possible to produce a product having excellent appearance quality, and it is possible to efficiently perform mass production at low cost by exhibiting excellent productivity. . Therefore, the present invention greatly contributes to industrial development as a method of manufacturing a seat cover that has eliminated the conventional problems.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a molding process of a seat cover according to an embodiment of the present invention.

FIG. 2 is a sectional view of a seat cover manufactured according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber web layer 1a Filament of high melting point fiber 1b Filament of low melting point fiber 2 Skin material 3 Adhesive layer 4 Backing base cloth 10 Needle punch machine 11 Heat setting room 11a Heating zone 11b Cooling zone 12 Pressurizing plate

Claims (7)

[Claims] An air-permeable skin material is laminated on a surface of a fiber web layer using a low-melting fiber at least in part via a heat-meltable adhesive layer, and the adhesive layer is melted by passing hot air. In the method of manufacturing a seat cover in which the skin material is adhered to the fiber web layer and the fiber web layer is heat-set, the fiber web layer and the skin material are not positively pressed from the front side of the skin material without actively pressing the fiber web layer and the skin material. Immediately after supplying the hot air toward the back side of the fibrous web layer to melt the low melting point fiber and the hot-melt adhesive layer of the fibrous web layer,
These are cooled while positively pressing with a pressure plate,
A method for producing a seat cover, comprising: bonding a skin material while pressing and smoothing the surface of a fiber web layer in a molten state and an adhesive layer, and compressing the fiber web layer to a predetermined thickness. 2. The method for manufacturing a seat cover according to claim 1, wherein the temperature of the pressure plate is adjusted to 30 ° C. or less. 3. The method for producing a seat cover according to claim 1, wherein the skin material is a fabric having a raised surface. 4. A backing fabric comprising a high-density nonwoven fabric structure is laminated on the back surface of the fiber web layer.
The method for manufacturing a seat cover according to item 1. 5. The method for manufacturing a seat cover according to claim 1, wherein the stacked materials are stacked by needle sticking before supplying hot air. 6. The fiber web layer is a mixed fiber web layer of high melting point fibers and low melting point fibers.
Or the method of manufacturing a seat cover according to 4 or 5. 7. The method of manufacturing a seat cover according to claim 6, wherein the low-melting fiber is a core-sheath fiber obtained by coating a high-melting core material with a low-melting sheath material.