JPH11113687A - Seat support, kit for seat support and preparation of seat support - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simplify constitution and to make handling properties good by forming a sheet support of a cured resin prepd. by curing a curable resin impregnated in a foamed body with intercommunicated foams into a shape fitted to the seating form of each person and a gas permeable cover covering the foamed body. SOLUTION: A kit 1 for a seat support is constituted of a foamed body 2 impregnated with a curable resin, a gas permeable cover 3 covering the foamed body 2 and a hermetic bag 4 sealed so as to prevent the curable resin with which the foamed body 2 is impregnated from being cured. A seat support with a shape fitted to the seating shape of each person is prepd. by a method wherein the hermetic bag 4 of this kit 1 for a seat support is opened and after the foamed body 2 is set on a seat, one sits down on the seat and the foamed body 2 is curd under a condition where the foamed body is deformed and pressed. As the foamed body 2, fixable foamed-polyurethanes, etc., are suitable from the points of flexibility and elasticity and their porosity are pref. 80-98 vol.%. Pref. examples of the curable resins are acrylics, silicone resins, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a seat support used for sitting on a seat of a passenger car and the like, a kit used for the seat support, and a method of manufacturing the seat support. The present invention relates to a support, a kit by which an individual can form such a seat support, and a method of manufacturing the seat support.

[0002]

2. Description of the Related Art Since the seats of various types of passenger cars are manufactured so as to be suitable for the average user, some users may lack a fit. In particular, a space is formed between the lower part of the back and the back from the seat to the backrest portion of the seat. However, since the size of the space differs depending on the person, some people suffer from back pain due to long hours of driving or the like. Also, in the case of sports-type passenger cars, many drivers prefer a seat that wraps the body completely.

In view of such circumstances, various types of seat supports have been proposed and some of them have been put to practical use. For example, Japanese Utility Model Laid-Open No. 3-74846 discloses a lumbar pillow for an automobile seat comprising a lumbar pillow main body, a belt body of an adjustable length for suspending the lumbar pillow, and a support for the belt body. Japanese Utility Model Laid-Open No. 1-97754 discloses an air-type lumbar support having a support mat formed of an elastic body which can be laid on the front surface of a seat back and can be expanded and contracted by supplying and discharging air. However, each of these supports has a disadvantage that it cannot be formed in a shape corresponding to the sitting posture of each person.

Therefore, a seat support capable of being formed into a shape corresponding to the posture of each occupant has been desired, and several proposals have been made. For example, Japanese Patent Application Laid-Open No. 1-299508 discloses that a liquid room-temperature foam material is injected into a flat bag-like cushion skin made of a moisture-proof and breathable material, and the injection port is closed. It is used by placing it along the seating surface and / or backing surface, seating the user of the chair on the seat and waiting for the foaming reaction of the foam material.After the foaming is completed, use the cushion from the chair. The present invention discloses a method for producing a personal-use auxiliary cushion for a chair, characterized in that a cushion conforming to the physique of a person is obtained. A urethane raw material liquid is used as a liquid room temperature foam material. However, in this method, since the liquid room temperature foam material is foamed, the strength and hardness of the completed cushion are not sufficient, and the work of injecting the liquid room temperature foam material into the cushion skin is also troublesome. Further, it is very difficult to adjust the injection amount of the liquid room temperature foaming material to obtain a desired hardness, and it is practically impossible for a general user to produce a satisfactory cushion.

Japanese Utility Model Application Laid-Open No. 3-64063 discloses a method of packing a spherical particle made of a synthetic resin into a rectangular air-tight bag so that it can move freely, hermetically sealing the bag, and attaching an air opening / closing valve to the end of the bag. Is disclosed. However, the overlay packed with spherical particles does not have shape retention and lacks fit.

[0006] Japanese Patent Application Laid-Open No. 2-224707 discloses that a fluid curable synthetic resin and a fluid curable synthetic resin are placed in a hollow bag made of a flexible material disposed on a surface side of a support of a seat and / or a backrest of a chair. After injecting a mixture (two-part curing type) with a catalyst or a curing agent to be cured, a chair is characterized by applying a load of a human body or a model of a human body to the bag to deform and fix the shape of the bag. A method for manufacturing a sheet core is disclosed. In this case, open-cell soft synthetic resin (sponge-like)
Impregnated with a fluid curable synthetic resin and one of a catalyst and a curing agent, wrapped in a bag in advance, and subsequently injecting the other, the impregnated material blows out of the sponge-like synthetic resin when externally pressurized, and the curable synthetic resin Mixing of the resin and the curing agent is promoted. This system is a two-part curing type. However,
Injecting the flowable curable synthetic resin, catalyst or curing agent into the bag is not only troublesome, but also has a limited pot life,
In addition, there is a problem that it is difficult to wash when the hands and clothes of the worker become dirty.

Japanese Unexamined Utility Model Publication No. 2-16005 is a seating shape memory member which is arranged on the surface of a seat and stores the seating shape of the seat when the human body is hardened while seated on the seat. Disclosed is a seat seating shape memory member having a main body configured, a heating member provided inside the main body, and means for switching the heating member between a heated state and a non-heated state. However, there is a disadvantage that the provision of the heating member and the switching means complicates the entire structure and increases the cost.

Accordingly, an object of the present invention is to provide a seat support which can be cured into a shape conforming to the seating shape of each person, can maintain the cured shape, and has a simple structure, so that it is easy to handle. That is.

Another object of the present invention is to provide a kit for forming the above-mentioned seat support.

Still another object of the present invention is to provide a method for manufacturing the above-mentioned seat support.

[0011]

Means for Solving the Problems As a result of intensive studies in view of the above-mentioned objects, the present inventors have found that a foamed body having interconnected air bubbles is impregnated with a curable resin in advance, and cured while seated. By doing so, it was discovered that the seat support can be formed into a shape that matches the seating shape of each person, and that the cured shape can be maintained, and the present invention has been reached.

That is, the seat support of the present invention has a shape conforming to the seating shape of each person, (a) a foam having open cells, and (b) a curable resin impregnated in the foam. Are characterized by having a cured resin cured to a shape conforming to the seating shape of each person, and (c) a cover for covering the cured foam.

[0013] The seat support kit of the present invention comprises:
It is cured according to the seating shape of each person, (a) a foam having open cells and impregnated with a curable resin, (b) a breathable cover covering the foam, (c)
And an airtight bag that seals the foam.

[0014] The method of the present invention for manufacturing a seat support that retains a shape conforming to the seating shape of each person includes: (1) (a) a foam having open cells and impregnated with a curable resin; b) a breathable cover covering the foam,
(c) using a kit comprising an airtight bag for sealing the foam, (2) opening the airtight bag, (3) sitting after setting the foam on a sheet, (4) Deforms foam
It is characterized in that it is cured in a pressed state.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION

[1] Seat support kit As shown in FIG. 1, the seat support kit 1 of the present invention
Is a foam 2 impregnated with a curable resin, a breathable cover 3 covering the foam 2, and an airtight bag 4 hermetically sealed so as to prevent the curable resin impregnated in the foam 2 from being cured. Consists of Hereinafter, each component will be described.

(A) Foam having open cells The foam 2 having open cells is preferably a soft foam polyurethane from the viewpoint of flexibility and elasticity. The porosity (foaming rate) of the foam 2 is preferably 80 to 98% by volume. If the porosity of the foam 2 is less than 80% by volume, the foam 2 lacks flexibility and the impregnation amount of the curable resin is insufficient. Not only becomes insufficient, but also the amount of the curable resin used becomes too large. A more preferred porosity is 90 to 97% by volume.

The outer shape of the foam 2 is formed into a desired shape of the sheet support. The portion of the foam body 2 that comes into contact with the lumbar vertebrae must be significantly deformed and have sufficient rigidity to support the lumbar vertebrae after being formed into a seat support. Therefore, as shown in FIG. 1, the foam 2 preferably has a cross-sectional shape (for example, a trapezoid) in which the portion in contact with the lumbar spine is relatively thick.

(B) Curable Resin As the curable resin impregnated in the foam 2, it is preferable to use a type which cures by contact with air. Since air contains water vapor in addition to oxygen, a curable resin in which a curing reaction proceeds by oxygen and / or water vapor is preferable. Specifically, an oxygen / moisture curable type such as an acrylic type, a silicone resin type, and a urethane type is preferable.
As such a curable resin, Cemedine Super X,
Cemedine Super XL and the like (manufactured by Cemedine Co., Ltd.) are commercially available. In addition, these commercial products have elasticity even after curing, and are more preferable in sitting comfort.

The weight ratio of the curable resin to the foam 2 is preferably 0.5: 1 to 5: 1, and 1: 1 to 5:
1 is more preferred. If the weight ratio is less than 0.5: 1, the curable resin will be insufficient, and it will not be possible to cure while maintaining the seated shape. On the other hand, if the weight ratio exceeds 5: 1,
The seat support loses its flexibility and becomes too stiff.

(C) Breathable Cover The breathable cover 3 is preferably formed of a stretchable woven cloth so that wrinkles and the like are not formed due to deformation of the foam 2.
Examples of such a woven cloth for the cover 3 include cotton cloth, knit, and Gore-Tex. The cover 3 is sewn in a bag shape except one side, and the opening is formed with a fastener or a magic tape 3.
It is convenient to make the shape sealed by a or the like.

(D) Hermetic bag The hermetic bag 4 is used to seal the foam 2 impregnated with the curable resin and to shield it from the air. In particular, when a curable resin that cures when it comes into contact with oxygen or water vapor in the air is used, the curing progresses during storage if there is no high airtightness. Examples of the material of the airtight bag 4 include polyolefin-based films such as polyethylene, polypropylene, and poly-4-methylpentene-1, and polyester-based films such as polyethylene terephthalate on which aluminum is vapor-deposited, aluminum foil laminated, and the like. Is preferred. In addition, as a product form, FIG.
It is preferable to seal the inside of the airtight bag 4 with the foam 2 wrapped in the air permeable cover 3 as shown in FIG.

In order to minimize air remaining in the airtight bag 4, it is preferable to perform vacuuming or purging with nitrogen gas. Even in the case of replacement with nitrogen gas, it is preferable to sufficiently reduce the pressure so that the airtight bag 4 does not burst due to a rise in the temperature inside the airtight bag 4. Further, if the container is hermetically sealed in a state of being evacuated, the package can be reduced in size, and the transportation cost and the storage cost can be reduced.

(E) Others It is difficult to completely remove the residual air or the organic solvent even by vacuuming or purging with nitrogen gas.
It is preferable that a desiccant, an adsorbent, an oxygen scavenger and the like are put in the inside. The desiccant absorbs and adsorbs residual water vapor, and examples thereof include silica gel, and commercially available products such as SECARD (manufactured by Shinagawa Kasei Co., Ltd.). The adsorbent mainly adsorbs the residual organic solvent, and includes activated carbon, sepiolite and the like. The oxygen absorber absorbs residual oxygen, and for example, a commercially available oxygen-free Z-20PT (manufactured by Mitsubishi Gas Chemical Co., Ltd.) can be used. In addition, a deodorant, a preservative, a fungicide, a fragrance, etc. may be contained in the curable resin, or may be put in the airtight bag 4.

[2] Manufacturing method of sheet support (1) Impregnation of curable resin

When the curable resin for impregnation is in a liquid state, it can be impregnated into the foam 2 as it is. However, from the viewpoint of workability, it is preferable to use a solution to reduce the viscosity. As the solvent to be used, a saturated aliphatic hydrocarbon-based organic solvent such as hexane, isohexane, heptane, octane, nonane, and decane is preferable from the viewpoint of easy removal and solubility of the curable resin. The resin concentration is not particularly limited as long as the curable resin solution has an appropriate viscosity.

The curable resin may be impregnated uniformly throughout the foam 2 or may be impregnated mainly in the deformed portion.
As the impregnation method, the foam 2 is sprayed with a solution of the curable resin, or the foam 2 is immersed in the solution of the curable resin, and then rubbed sufficiently in a plastic bag and uniformly dispersed in the foam 2. Fig. 2
And a method of injecting a curable resin into a spotted or striped pattern in the foam 2 by using the apparatus shown in FIG.

In FIG. 2, reference numeral 10 denotes a manifold type nozzle. The pipe 12 communicates with a supply source (not shown) of a hardening type resin solution, and a plurality of nozzles 14 communicate with the pipe 12 via a branch portion 13. , 14... Manifold type nozzle
When injecting the curable resin solution into the foam 2 by using the nozzle 10, first, the nozzle portions 14, 14,.
Is pressed against the foam 2 to make the foam 2 crushed. Next, a curable resin solution is supplied from the pipe 12 at a high pressure, and injected into the foam 2 from the plurality of nozzles 14, 14. When the manifold type nozzle 10 is removed, the foam 2 returns to its original shape, and the curable resin solution is in a state of being injected only in the vicinity of each of the nozzle portions 14, 14,. FIG. 3 shows each nozzle unit 14,
When 14... Are dotted, the distribution of spots 25 of the impregnated curable resin 26 is shown. Of course, each nozzle part 14, 14 ...
When is a slit shape, the distribution of the impregnated curable resin becomes linear. When the curable resin is impregnated in the spot-like or striped pattern, the cover 3 of the deformed and cured sheet support 3
This is preferable because wrinkles are not easily formed. Also here, the nozzle part
Injecting the curable resin while moving the needle tip with 14 as an injection needle makes it easier to control the distribution of the injection amount into the foam 2.

(2) Encapsulation in an airtight bag After completion of impregnation, the organic solvent is removed by appropriately reducing the pressure. When the organic solvent remains, a peculiar smell is generated when the airtight bag 4 is opened. After the removal of the organic solvent, the foam 2 is covered with a cover and placed in an airtight bag 4 together with a desiccant, an adsorbent, an oxygen scavenger and the like. Next, the airtight bag 4 is sealed by heat sealing or the like by reducing the pressure or replacing with nitrogen gas. In addition, as described above, if the package is sealed only by the reduced pressure, the package can be reduced.

(2) Formation of Seat Support The airtight bag 4 is opened, and the foam 2 impregnated with the curable resin is set at a predetermined position on a seat 20 such as a car, as shown in FIG. Since the foam 2 is initially flexible, when it is seated on the seat 20, it deforms according to the seating posture of each person.
Since the oxygen and water vapor in the air come into contact with the curable resin in the foam 2 through the air permeable cover 3, the curable resin in the foam 2 starts curing while sitting, and takes about 30 minutes to 2 hours. It cures to the extent that the seating shape is maintained. At this stage, a seat support that retains a desired seating shape can be obtained even if the user separates from the seat 20, but the user may sit still until the curing is completed. Thus, for example, if the foam 2 impregnated with the curable resin is placed on the sheet 20 during operation, the seat support can be easily formed.

It is preferable that the time required for the curable resin to cure to the extent that the seating shape is maintained is about 30 minutes to 2 hours as described above. If it is less than 30 minutes, curing is too fast,
In addition to some progress of curing in the manufacturing process, there are problems that some users have too little room to take a sitting posture. If the time is longer than about 2 hours, the user often feels it is too long. In particular, it is preferable that the setting is made so as to maintain the seating shape in 30 minutes to 1 hour.

[3] Seat Support As shown in FIG. 4, the foam 2 is deformed according to the sitting posture of each user, and is cured so as to maintain its shape. It will have a perfectly fitted shape. As shown in FIG.
Since the hardening resin is impregnated in the foam 2 having a thick portion in contact with the lumbar portion, the portion in contact with the lumbar portion (the portion requiring the highest strength and hardness) after deformation and hardening is reduced. It is hardened by the curable resin. Therefore, a seat support having a structure in which a portion requiring the most strength and hardness is reinforced most with a cured resin is obtained. Also,
The portions that protrude from the waist in both lateral directions are softly deformed and hardened so as to surround the waist, and also exhibit a so-called side support effect that suppresses the sideslip of the waist.

[0032]

EXAMPLES The present invention will be described in more detail with reference to the following Examples, but it should not be construed that the invention is limited thereto.

Example 1 170 g of isohexane was mixed with 340 g of a curable resin-based adhesive (Cemedine Super XL, manufactured by Cemedine Co., Ltd.), and this was mixed with a flexible polyurethane foam having a cross-sectional shape shown in FIG. (A porosity of 97% by volume) in a polyethylene bag and rubbed sufficiently for about 2 minutes. Then, the pressure was reduced by a vacuum pump for 4 minutes to completely remove isohexane. The foam impregnated with the adhesive in this way was covered with a knit cover. The time required so far was a total of 15 minutes.

The adhesive-impregnated foam covered with the cover is shown in FIG.
After leaning on the seat back of the car as shown in
He sat in the seat and continued driving for 20 minutes. During operation, the adhesive impregnated foam was pressed into the driver's lumbar region and remained deformed. The seat support obtained in this manner retained the sitting shape, fitted perfectly to the lumbar vertebrae, and had a satisfactory seating feeling with remaining flexibility in other parts.

Example 2 340 g of a curable resin-based adhesive (Cemedine Super XL, manufactured by Cemedine Co., Ltd.) using a manifold type nozzle shown in FIG.
Was injected into the same foam as in Example 1. Nozzle spacing is 40
mm. Next, after being covered with a knit cover in the same manner as in Example 1, it was placed on a seat and seated. The time required so far was 10 minutes in total. During operation, the adhesive impregnated foam was pressed into the driver's lumbar region and remained deformed. After a lapse of 20 minutes in this state, a seat support having a satisfactory sitting feeling while maintaining the seating shape was obtained.

Example 3 An adhesive-impregnated foam with a cover produced in the same manner as in Example 1 was dried with a desiccant [“Secard” (Shinagawa Kasei Co., Ltd.)
)) And an oxygen scavenger [“Ageless Z-20PT” (manufactured by Mitsubishi Gas Chemical Co., Ltd.)], and placed in an aluminum foil / polyethylene laminated film. After being left for 3 months, it was opened, and cured for 30 minutes while sitting in the same manner as in Example 1. As a result, a seat support that maintained the sitting shape and had a satisfactory seating feeling was obtained.

Example 4 An adhesive-impregnated foam with a cover prepared in the same manner as in Example 2 was dried with a desiccant [“Secard” (Shinagawa Kasei Co., Ltd.)
)) And an oxygen scavenger [“Ageless Z-20PT” (manufactured by Mitsubishi Gas Chemical Co., Ltd.)], and placed in an aluminum foil / polyethylene laminated film. After leaving it for 3 months, it was opened, and cured for 30 minutes while sitting in the same manner as in Example 2. As a result, a seat support having a satisfactory seating shape and a satisfactory seating feeling was obtained.

The present invention has been described with reference to the drawings.
The present invention is not limited thereto, and various changes can be made without departing from the spirit of the present invention.

[0039]

The seat support of the present invention is easy to handle because it is cured while sitting on a foamed body having interconnected cells impregnated with a curable resin. In addition, by using a curable resin that cures by contact with air, it is possible to easily form a seat support that retains the seated shape simply by maintaining the seated state. Although the shape of the seat support is all different depending on the body shape and posture of each user, the seat support of the present invention is very adaptable, and can be formed into a seating shape satisfying any user. Further, since the foam having interconnected air bubbles and the air permeable cover are used, the air permeable material has air permeability even after curing, so that there is no danger of operating for a long time. The seat support of the present invention having such features is particularly suitable as a seat support for supporting a lumbar spine.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an example of a seat support of the present invention.

FIG. 2 is a schematic cross-sectional view showing a state where a curable resin is injected by a manifold type nozzle.

FIG. 3 is a partial sectional perspective view showing a foam in which a curable resin is injected into a spot-like pattern.

FIG. 4 is a schematic view showing a state in which a seat support that retains a seating shape is formed from an adhesive-impregnated foam with a cover placed on a seat.

[Explanation of Signs] 1 ... Seat support 2 ... Foam body having open air bubbles 3 ... Ventible cover 4 ... Airtight bag 10 ... Manifold type nozzle

Claims (9)

[Claims] 1. A seat support which retains a shape conforming to a seating shape of an individual, wherein (a) a foam having open cells and (b) a curable resin impregnated in the foam. A cured resin that has been cured into a shape that matches the shape of the person sitting,
(c) a sheet support having a cover for covering the cured foam. 2. The seat support according to claim 1, wherein the curable resin is of a type that cures by contact with air, and is cured in a seated state. 3. A kit for seat support which is cured according to the seating shape of each person, comprising: (a) a foam having open cells and impregnated with a curable resin; A seat support kit comprising: an air-permeable cover to be covered; and (c) an air-tight bag that seals the foam. 4. The seat support kit according to claim 3, wherein the curable resin is of a type that is cured by contact with air. 5. The sheet support kit according to claim 3, wherein the curable resin is injected into the foam in a spotted or striped pattern. 6. The seat support kit according to claim 3, wherein the inside of the airtight bag is replaced with nitrogen. 7. The kit for seat support according to claim 3, wherein the inside of the airtight bag is substantially vacuum. 8. The seat support kit according to claim 3, wherein the impregnated amount of the curable resin is the largest in a foam portion that comes into contact with the waist of a seated person. Kit. 9. A method for manufacturing a seat support that retains a shape conforming to a seating shape of each person, comprising: (1) (a) a foam having open cells and impregnated with a curable resin; Using a kit comprising a breathable cover for covering the foam, and (c) an airtight bag for sealing the foam, (2) opening the airtight bag, and (3) a sheet for the foam And (4) curing the foam in a deformed and pressed state.