JPH11137869A - Manufacture of wadding material for vehicle seat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wadding material in prescribed thickness with large restoring force against pressure in the thickness direction by heat-setting crimp fiber filament under a temperature lower than that of primary crimp to crimp the crimped fiber filament again. SOLUTION: A fiber web 1 is guided into a heating zone 10 where hot wind at 160-180 deg.C, which is a temperature lower than the melting point of crimped fiber filament 2 but can generates crimp, is flowing in the vertical direction by a conveyor 10a. The hot wind is passed through fiber web 1 in the thickness direction. The heat treatment is carried out to generate primary crimp of the crimped fiber filament to constitute the fiber web 1. Since needle punching is not applied yet to the fiber web, fiber filament is not entangled with each other. Since the crimping tendency of the crimped fiber filament 2 is never limited, the filament 2 is brought into a sufficiently crimped condition. It is important for improving the cushioning performance to carry out heat treatment before needle punching.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a wading material for a vehicle seat having a soft feeling and excellent cushioning properties.

[0002]

2. Description of the Related Art As a wading material for a vehicle seat of this type, as shown in Japanese Utility Model Laid-Open No. 1-103400, a polyurethane foam having a large volume and a soft feeling and having excellent cushioning properties is used. Is widely known, but because the strength of the polyurethane foam is insufficient, a high-quality, high-quality skin material is used as a covering material to cover the polyurethane foam, which increases the cost. There were also problems in terms of waste pollution and recycling.

[0003] In order to solve such a problem, recently, there has been proposed a material in which a fiber web is used as a wadding material instead of a polyurethane foam. The former is soft because it has sufficient peel strength by being sufficiently entangled, or has heat-bondable fiber filaments mixed in the fiber web and is fused by fusing the fiber filaments during heat setting. The texture is difficult to obtain and is not suitable as a thick one, and the latter has problems such as poor sag resistance and high cost. Furthermore, both have the problem that the restoring force in the thickness direction is inferior and the cushioning property is poor.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and has a problem in terms of disposal pollution or recycling and a problem in strength. There is little or no polyurethane foam used, and it has a soft feel, has sufficient restoring force in the thickness direction, has excellent cushioning properties, and is resistant to thick materials. It is an object of the present invention to provide a method for manufacturing a vehicle seat wading material which can efficiently and inexpensively mass-produce a good vehicle seat wading material.

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, a method for producing a wading material for a vehicle seat according to the present invention comprises a method of producing a web material mainly comprising crimped fiber filaments which are crimped by heating. A carding machine is used to make a fibrous web, and hot air is passed through the web in the thickness direction to primary crimp the crimped fiber filaments. After being applied, the crimped fiber filaments are heat-set at a temperature lower than the primary crimp while being compressed between the press plates for heat setting, and the crimped fiber filaments are crimped again. A wadding material having a predetermined thickness and a large restoring force.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. In the present invention, first, two kinds of fibers having different heat shrinkage rates are bonded and crimped by a heat treatment.
A fiber web 1 having a basis weight of about 200 to 600 g / m ² and a thickness of about 5 to 20 mm by using a web raw material mainly comprising
And As the crimped fiber filament 2 described above, for example, a fine denier of 3 denier or less in which a polyester fiber and a polyamide fiber having a high melting point of about 220 to 230 ° C. but different in heat shrinkage are laminated. As the main material, but with the crimped fiber filament 2
The same amount of processed filaments as the core filaments such as fine denier high melting point fiber filaments and the like are coated with a lubricating resin coating whose melting point is significantly higher than the heat setting temperature and has low frictional resistance, such as silicon resin and fluororesin. May be. At this time, the crimped fiber filaments 2 forming the fibrous web 1 are stretched by a carding machine so that the degree of crimp is reduced to some extent.

Next, the fiber web 1 is transferred to a conveyor 10a.
160 to 180 ° C., which is lower than the melting point of the crimped fiber filament 2 but is a temperature at which crimping is developed.
Is introduced into the heating zone 10 in which the hot air flows in the vertical direction, and the hot air is passed in the thickness direction of the fibrous web 1 (in the drawing, from the top to the bottom). This heat treatment is performed to develop a primary crimp of the crimped fiber filaments 2 constituting the fiber web 1. In this case, since the fiber web 1 has not yet been subjected to needle sticking, The fiber filaments are not intertwined with each other, and therefore, the crimping tendency of the crimped fiber filaments 2 by heating is not limited at all, so that the fibers are in a sufficiently crimped state. As described above, it is particularly important in the present invention that the heat treatment as described above is performed before the needle piercing process and the primary crimp is performed, and the cushioning feeling and the restoring force of the wadding material described later are further improved. You do it.

Next, the obtained fiber web 1 is naturally cooled, and then subjected to needle sticking by a needle punching machine 11. This needle piercing process is not a large-scale needle piercing process as in the prior art, but is a needle piercing process with a pene number of about 10 to 30 needles / cm ^2, which is the minimum necessary for preventing peeling of the crimped fiber filament 2. In this case, the crimped fiber filaments 2 may be partially entangled by the small needle piercing portion 3.

The fibrous web 1 which has been subjected to the minimum needle piercing process in order to prevent peeling in this manner is then subjected to the heating zone 13
And the cooling zone 14 are communicated with each other. First, between the presser plates 12 and 12 for a belt-conveyor-type heat set having a thickness equal to or slightly smaller than the product thickness to be obtained. While compressing at
If the crimped fiber filament 2 is subjected to heat setting at a temperature lower than the primary crimp, the crimped fiber filament 2 is re-crimped. A wading material having a large predetermined thickness can be obtained. The heat setting process in this step is not a large-scale process in which the fiber filaments are partially fused by performing at a temperature equal to or higher than the conventional melting temperature of the fiber filaments. The distance between the two upper and lower heat-setting holding plates 12, 12 which can be adjusted so as to be a product thickness or slightly smaller than the product thickness.
2 and 12, the fiber web 1 is compressed in the vertical direction, and hot air is blown in the thickness direction so as to have a temperature lower than the melting point of the crimped fiber filament 2 of about 130 to 150 ° C. but heat settable. And heat-set. Further, after the above-described heating treatment is performed in the heating zone 13, the cooling treatment is performed by the cool air in the cooling zone 14, and the heat setting is completed. Two heat-sets before and after the needlestick process provide a precise, entangled, non-fused, yet fully crimped, restoring force against pressure in the thickness direction The wadding material 20 has a large thickness and a predetermined thickness.

The wadding material 20 is a fiber web 1
Only the needle piercing process and the heat setting process under the above conditions may be applied to only the fiber web 1, but the needle piercing process is performed by attaching a backing base fabric 21 such as a spunbonded nonwoven fabric to the back surface of the fiber web 1. By applying heat setting to the backing cloth 20, as shown in FIG. 2, a backing base cloth 21 that has been needle-pierced together with the wadding material 20 is attached to the back surface of the wadding material 20 to improve sewing workability and tensile strength. This can provide more excellent elasticity.

When the thus constructed one is used in the same manner as a conventional wading material for a vehicle seat, the wading material 20 is applied to the fibrous web 1 made of fine denier and high melting point crimped fiber filaments 2 to prevent peeling. In addition to forming the minimum necessary needle sticking portion 3 to eliminate peeling, the crimped fiber filament 2 is thermally deformed and entangled without partial fusion by heat setting under pressure. Such a fiber web is mechanically entangled by needle piercing and mechanically entangled to give a peel strength, or a heat-adhesive fiber filament is mixed in the fiber web and the fiber filaments are fused together during heat setting and peeled. As a result, a much softer texture can be obtained as compared with the one having the strength. Moreover, the crimped fiber filament 2 which is the main material of the fiber web 2
Is subjected to a heat treatment before the needle sticking process and is in a state where the crimp is sufficiently developed.
Exerts a sufficient restoring force in the thickness direction by the action of the crimped fiber filaments 2 and provides an excellent cushion feeling. The manufacturing method according to the present invention can mass-produce the inexpensive mass of a wading material for a vehicle seat having a soft feeling and an excellent cushioning property and excellent in settling resistance.

[0012]

As is apparent from the above description, the wading material for vehicle seats of the present invention reduces or does not use polyurethane foam which has problems in terms of disposal pollution or recycling and also has a problem in strength. It has a soft feel, has a sufficient restoring force in the thickness direction, has excellent cushioning properties, and can be used efficiently as a thick wading material for vehicle seats. It can be mass-produced well at low cost. Therefore, the present invention greatly contributes to the development of industry as a method for manufacturing a wading material for a vehicle seat that has eliminated the conventional problems.

[Brief description of the drawings]

FIG. 1 is a process explanatory view showing an embodiment of the present invention.

FIG. 2 is a sectional view of a wadding material obtained by the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wadding material 2 Crimped fiber filament 3 Needle piercing part 20 Wadding material 21 Back base cloth

Claims (2)

[Claims] A web material mainly composed of crimped fiber filaments crimped by heating is made into a flocculated fibrous web by a carding machine, and hot air is passed through the web in the thickness direction to reduce the crimped fiber filaments. Primary crimp, then
The fiber web is subjected to a minimum needle piercing process to prevent peeling, and the crimped fiber filament is heat-set at a temperature lower than the primary crimp while being compressed between the press plates for heat setting. A method for manufacturing a wading material for a vehicle seat, comprising: re-crimping a compressed fiber filament to form a wadding material having a predetermined thickness having a large restoring force against pressure in a thickness direction. 2. The method for manufacturing a wading material for a vehicle seat according to claim 1, wherein the backing fabric is overlaid on the fiber web and needle piercing is performed.