JPH10128890A - Cushion base material as well as cushioning material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simply manufacture a cushioning material of a shape having a round corner without becoming sweaty and without deteriorating cushioning performance. SOLUTION: Outer layers 2 formed of blended cotton made of polyester resin fiber having small thickness than that of fiber of a fiber assembly core 1 are superposed on upper and lower surfaces of the core 1 having a cubic structure including cushioning properties by three-dimensionally entangling fibers of suitable lengths and made of polyester resin via polyester hot melt sheets 3. Then, a skin material 7 is superposed on a lower surface of the lower layer 2 via the sheet 3. Thereafter, this superposed material is heated, compressed and then cooled in molds 11, 12 having cavities 10a, 10b of predetermined cushioning material shape, and removed from the molds.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion base or cushion body for use in chairs, sofas, automobile seats, etc., a cushion base or cushion body for use in mattresses, pillows and the like in beds and the like, and to a method of manufacturing the same. It is.

[0002]

2. Description of the Related Art Conventionally, as a cushion body for a seat portion of a chair or a sofa, a cushion base made of a soft urethane foam foamed and formed into a shape of a predetermined seat body or a backrest portion is covered with an outer fabric. The shape of the specified cushion base is completed by laminating a plurality of layers of completed cushioning materials with different cushioning performance (elasticity), which are made by intertwining synthetic fibers such as polyester resin fibrous fibers into a cotton-like shape and forming a plate state. After forming the cushion base by heating and compressing it in a molding die having the cavity described above, air cooling is performed to form a cushion base, and the cushion base is covered with an outer fabric to complete a cushion body.

[0003]

However, since the soft urethane foam has a relatively high material density and low air permeability, for example, in a chair or a bed mat, sweating from the surface of a human body causes stuffiness at a contact portion with the human body. easy, further, there are drawbacks such as causing air pollution NO _X gas or CN gas when burning and disposal occurs.

[0004] On the other hand, when a synthetic fiber cotton sheet made of polyester resin fiber or the like is laminated and adhered, there has been a problem that, over a long period of use, appearance deformation (set) becomes severe and elasticity is reduced. An object of the present invention is to provide an environment-friendly cushion base or cushion body that is resistant to stuffiness, has excellent cushioning properties and durability, and is environmentally friendly.

[0005]

According to a first aspect of the present invention, there is provided a cushion base comprising a three-dimensionally entangled fiber of an appropriate length made of polyester resin and having cushioning properties. An outer layer made of a blended cotton material made of a polyester resin fiber or the like having a smaller thickness than the fibers of the fiber assembly core is adhesively coated on the outer peripheral surface of the fiber assembly core having the structure.

The cushion body according to the second aspect of the present invention has a three-dimensionally entangled fiber made of a polyester resin and has a three-dimensional structure. An outer layer made of a blended cotton material made of a polyester resin fiber or the like thinner than the fibers of the fiber aggregate core is adhesively coated, and at least one surface of the outer layer is adhesively coated with a skin.

Further, according to a third aspect of the present invention, there is provided the cushion substrate manufacturing method, wherein fibers of an appropriate length made of a polyester resin are three-dimensionally entangled with each other to provide a three-dimensionally structured fiber assembly core having cushioning properties. A step of interposing an adhesive between the surface and an outer layer made of a blended cotton material made of a polyester resin fiber or the like having a smaller thickness than the fiber of the fiber assembly core, and having a cavity having a predetermined cushion base shape And cooling after heating and compression by a molding die.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a cushion body, wherein fibers of an appropriate length made of polyester resin are three-dimensionally entangled on a three-dimensionally structured fiber assembly core having cushioning properties. On the lower surface, an outer layer made of a blended cotton material made of a polyester resin fiber or the like having a smaller thickness than the fiber of the fiber assembly core is laminated via an adhesive, and then an adhesive is applied to the outer surface of the at least one outer layer. Then, the skins are stacked on each other, and then the stacked ones are heated, compressed, and cooled in a molding die having a cavity having a predetermined cushion shape.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment in which the present invention is applied to a cushion base or a cushion body of a seat or a backrest in a chair will be described. 1 (a) to 1 (d) show a method for manufacturing a cushion base of the present invention, and FIGS. 2 (a) to 2 (c) show a method for manufacturing a cushion body. The cushion base 5 here does not include the skin (outer surface), and the one formed integrally with the skin (outer surface) is referred to as the cushion 6.
The fiber aggregate core 1 having cushioning properties of the present invention has a thickness (about 0.2 mm to 1.0 mmd) made of polyester resin,
A large number of fibers of an appropriate length are randomly curved three-dimensionally, and are bonded and bonded with an adhesive or the like at an adjacent portion or an intersecting portion between the fibers (hereinafter, this state is referred to as confounding). The fiber assembly core 1 is configured to have cushioning properties, and the thickness of the fiber assembly core 1 is a mat shape of about 10 cm to 20 cm in an uncompressed state (free state). The outer layer body 2 is made of a blended cotton such as a saturated polyester resin fiber and a low-melting polyester resin fiber having a smaller thickness (about 2 denier to 100 denier) than the fiber of the fiber aggregate core 1 and has a non-thickness dimension. 5mm in compressed state (free state)
It is formed on a hard cotton board with a relatively low elasticity of about 2cm.

[0010] The hot melt sheet 3 is a heat-activated adhesive, has a film shape or a sheet shape, and is softened (melted) by heating without a solvent. Therefore, a high-speed bonding operation in which the bonding is completed when cooled after being heated and pressed on the member to be bonded can be performed. The adhesive for the hot melt sheet 3 includes a heat-meltable polymer (EYA), a polyester, an olefin, and a polyamide.

In the method of manufacturing the cushion base 5, FIG.
As shown in (a), a dimension L slightly larger than the shape and dimension of the cushion base 5 having a predetermined final shape (see FIG. 1D).
The hot melt sheet 3 is placed between the wide upper and lower surfaces of the fiber assembly core 1 cut into a plate shape (the width is also slightly larger but not shown) and the outer layers 2 and 2 having approximately the same area.
To form a five-layered body 4, and this five-layered body 4 is
Cavity (recess) 1 in the shape of a predetermined cushion base 5
It is inserted into upper and lower pairs of molding dies 11, 12 having 0a, 10b (see FIG. 1B).

Next, in the case of the polyester hot melt sheet 3 as an adhesive, the heating temperature (180 ° C. to 200 ° C.)
° C), compression ratio = about 0.6 to 0.8 (ratio of thickness of laminated body after compression / thickness of laminated body in free state (before compression))
Heating and compression for about 30 seconds to 300 seconds, and then in the same molds 11 and 12 at a temperature of about 20 ° C. to 40 ° C. for 180 seconds.
The process of cooling for about a second is performed (see FIG. 1C).

When such a manufacturing method is adopted, the outer layer bodies 2 and 2 having a small thickness are adhered to each other by the hot melt sheet 3 in which the outer peripheral surface of the fiber assembly core 1 is softened (melted) by the heating and compression. In addition, the compression by the upper and lower pair of molding dies 11 and 12 causes the outer layer body 2 in the form of a hard cotton plate to have the cavities 10a and 10a.
10b, the outer layers 2 and 2 also wrap around the end face in the thickness direction of the fiber assembly core 1, and completely cover the outer surface of the fiber assembly core 1 up and down. 2 and 2, and the shape of the predetermined cushion base 5 can be determined.

That is, even if the outer peripheral surface of the fiber aggregate core 1, particularly the end surface in the thickness direction is sharp, the outer peripheral surface of the fiber aggregate core 1 is formed by the outer layers 2 and 2 by pressure bonding. It can be completely covered and maintained in a rounded predetermined shape. In particular, when the end surfaces of the upper and lower outer layers 2 and 2 are continuously connected and bonded via the adhesive of the hot melt sheet 3, the fiber assembly core 1 in a slightly compressed state is completely wrapped, The shape of the cushion base 5 can be determined. Then, the cushioning property (whether hard or soft) of the portion of the fiber assembly core 1 in the completed cushion base 5
Can be arbitrarily adjusted by setting the compression ratio. The cushion base 5 formed in this manner can be covered with an outer skin (not shown) made of fabric or the like such as a chair seat in the same manner as a conventional soft urethane foam.

Further, in the cushion base 5, a portion of the fiber assembly core 1 having cushioning properties is made of a thick fiber, and a large number of fibers are randomly and three-dimensionally curved and entangled. Therefore, since the density is lower and the air permeability is higher than that of the conventional soft urethane foam, when used as a cushion, an effect is obtained that the contact portion with the human body is hardly stuffy. The cushion base 5 has a small appearance deformation (set) due to long-term use. For example, when the cushion base 5 is applied to a cushion of a seat body of a chair, weight can be dispersed in a wide range, and sitting comfort is improved.

[0016] Moreover, even when the incineration of unwanted items, such as soft urethane foam, NO _X gas and CN gas does not occur. Furthermore, if all the materials of the cushion base 5 are made of the same material such as polyester resin, it is easy to carry out separation work at the time of disposal, and it can contribute to recycling of raw materials. 2 (a) to 2 (c)
Is a skin 7 on at least one surface of the cushion base 5.
Is a method of manufacturing a cushion body 6 in which the cushion body 6 is integrally bonded to the cushion body 6. The dimension is slightly larger than the shape and dimensions of the cushion body 6 having a predetermined final shape (see FIG. A hot melt sheet is placed between the wide upper and lower surfaces of the fiber assembly core 1 cut into a plate shape of L1 (also slightly larger in width but not shown) and the outer layers 2 and 2 having substantially the same area as the hot melt sheet. 3 is formed into a five-layered body 4, and a skin 7 made of woven fabric or artificial leather is further disposed on the surface of at least one outer layer 2 of the five-layered body 4 via the hot melt sheet 3. Then, these are inserted into upper and lower pair of molding dies 11, 12 having cavities (recesses) 10a, 10b in the shape of the predetermined cushion body 6 (FIG. 2 (a)).
reference).

Next, in the case of the polyester hot melt sheet 3, the heating temperature (180 ° C. to 200 ° C.) and the compressibility =
After heating and compressing for about 30 to 300 seconds at about 0.6 to 0.8 (the ratio of the thickness of the laminated body after compression / the thickness of the laminated body in the free state (before compression)), the same molding Type 1
In steps 1 and 12, a step of cooling at a temperature of about 20 ° C. to 40 ° C. for about 180 seconds is performed (see FIG. 1C).

According to this manufacturing method, in addition to the same operation and effect as in the first embodiment, the cushion body 6 to which the skin body 7 is integrally bonded can be manufactured quickly. The operation and effect of the completed cushion body 6 are almost the same as those of the cushion base 5, and the fiber assembly core 1, the outer layer 2, the hot melt sheet, and the skin 7 are made of the same material such as a polyester resin material. With such a structure, it is easy to separate at the time of disposal at the same time as it is difficult to get stuffy, and it can contribute to recycling of raw materials.

In the manufacturing method, instead of using the hot melt sheet, an adhesive is formed in a tape shape to form a partial bonding portion, a viscous liquid hot melt type adhesive, a powdery hot melt type adhesive, A rubber-based adhesive may be applied to one or both of the outer peripheral surface of the fiber assembly core 1 and the surface of the outer layer body 2 in an intermittent or continuous band shape by a spray gun or the like.

[0020]

As described above, the cushion base according to the first aspect of the present invention is a three-dimensional fiber assembly having a cushioning property by three-dimensionally intermingling fibers of an appropriate length made of a polyester resin. An outer layer made of a blended cotton material made of a polyester resin fiber or the like having a smaller thickness than the fibers of the fiber assembly core is adhesively coated on the outer peripheral surface of the body core.

Therefore, in this cushion base, the core of the fiber assembly having cushioning properties is made of a thick fiber, and a large number of fibers are randomly and three-dimensionally curved and entangled. Since the density is lower and the air permeability is higher than that of the conventional soft urethane foam, when used as a cushion, an effect is obtained that the contact portion with the human body is hardly stuffy. In addition, this cushion base has little appearance deformation (set) due to long-term use. For example, when applied to a cushion of a chair seat, weight can be dispersed over a wide range, and sitting comfort is improved.

[0022] Moreover, even when the incineration of unwanted items, such as soft urethane foam, NO _X gas and CN gas does not occur. Furthermore, if the material of the cushion base is made of the same material such as polyester resin, it is easy to carry out separation work at the time of disposal, and it can contribute to recycling of raw materials. And the manufacturing method is
As described in claim 3, fibers of an appropriate length made of a polyester resin are three-dimensionally entangled with each other, and the outer peripheral surface of the fiber assembly core having a three-dimensional structure having cushioning properties is thinner than the fibers of the fiber assembly core. A step of inserting an adhesive between an outer layer made of a blended cotton material such as a polyester resin fiber having a thickness, and a step of cooling after heating and compression by a molding die having a cavity having a predetermined cushion base shape. Characterized by the following.

According to such a manufacturing method, even if the outer peripheral surface of the fiber assembly core, particularly the end surface in the thickness direction, is sharp, the outer surface of the thin fiber cotton sheet is formed by pressure bonding. As a result, it is possible to completely cover the outer peripheral surface of the fiber assembly core, and to easily hold the fiber assembly core in a predetermined round shape along the inner surface of the cavity of the molding die. Then, the cushioning property (whether hard or soft) of the fiber aggregate core portion in the completed cushion substrate
Has an effect that it can be arbitrarily adjusted by setting the compression ratio by a molding die.

The cushion body according to the second aspect of the present invention is characterized in that fibers of an appropriate length made of a polyester resin are three-dimensionally entangled with each other to form a three-dimensionally structured fiber assembly core having cushioning properties on the outer peripheral surface thereof. An outer layer made of a blended cotton material made of a polyester resin fiber or the like thinner than the fibers of the fiber aggregate core is adhesively coated, and at least one surface of the outer layer is adhesively coated with a skin.

Therefore, in addition to the above-described functions and effects of the cushion base, the skin can be mounted at once, so that the cushion can be easily attached later. In addition, if the same material including the outer skin is used, the separation work at the time of disposal is extremely easy. And Claim 4
The manufacturing method of the cushion body according to the invention described in the above, three-dimensionally entangled fibers of an appropriate length made of polyester resin to the upper and lower surfaces of a three-dimensional structure fiber aggregate core having a cushioning property, via an adhesive An outer layer made of a blended cotton material made of a polyester resin fiber or the like having a smaller thickness than the fiber of the fiber assembly core is stacked, and then an outer skin is stacked on the outer surface of the at least one outer layer with an adhesive, and then. The superposed products are heated and compressed in a molding die having a cavity having a predetermined cushion shape and then cooled.

Therefore, in addition to the function and effect of the cushion base manufacturing method according to the fourth aspect, the manufacturing process of the cushion body itself is simplified and the manufacturing cost can be greatly reduced.

[Brief description of the drawings]

FIG. 1 (a) shows a step of laminating an outer layer body on the upper and lower surfaces of a fiber assembly core via a hot melt sheet, and (b)
Shows the step of inserting the laminated product into the upper and lower molding dies, (c) shows the step of cooling after heating and compression in the upper and lower molding dies, and (d) is a cross-sectional view of the cushion base as a molded product Is shown.

FIG. 2 (a) shows an upper and lower molding die in which an outer layer body is laminated on the upper and lower surfaces of a fiber assembly core via a hot melt sheet, and a skin body is further arranged on the lower surface side via a hot melt sheet. (B) shows a step of cooling after heating and compression of the laminated product in the upper and lower molding dies,
(C) shows a sectional view of a cushion body as a molded product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber assembly core 2 Outer layer body 3 Hot melt sheet 4 Five-ply laminate 5 Cushion base 6 Cushion body 7 Skin body 11,12 Molding mold

Claims (4)

[Claims] 1. A three-dimensionally entangled fiber made of a polyester resin is three-dimensionally entangled with a three-dimensionally structured fiber assembly core having a cushioning property. A cushion base obtained by bonding and covering an outer layer made of a blended cotton material made of polyester resin fiber or the like. 2. A three-dimensionally entangled fiber made of a polyester resin is entangled three-dimensionally to form a three-dimensionally structured fiber aggregate core having a cushioning property on an outer peripheral surface of the fiber aggregate core. A cushion body in which an outer layer made of a blended cotton material made of polyester resin fiber or the like is adhesively coated, and at least one surface of the outer layer is adhesively coated with a skin. 3. An outer peripheral surface of a fiber assembly core having a three-dimensional structure having a cushioning property by three-dimensionally intermingling fibers of an appropriate length made of a polyester resin, and having a thickness smaller than the fibers of the fiber assembly core. A cushion comprising a step of interposing an adhesive between an outer layer made of a blended cotton material such as polyester resin fiber and the like, and a step of cooling after heating / compression by a molding die having a cavity having a predetermined cushion base shape. A method for manufacturing a substrate. 4. A fiber of a fiber aggregate core having a three-dimensional structure having cushioning properties by arranging fibers of an appropriate length made of polyester resin three-dimensionally, via an adhesive. An outer layer made of a blended cotton material made of a thinner polyester resin fiber or the like is stacked, and then a skin is stacked on the outer surface of the at least one outer layer via an adhesive, and then the stacked one is A method for manufacturing a cushion body, comprising heating and compressing in a molding die having a cavity having a predetermined cushion body shape, followed by cooling.