JPS6040239A - Integrally molded body - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention involves forming an integrally molded article, specifically a heat-formable tea liquid fiber web (hereinafter referred to as "web"), into a fiber cushion body (hereinafter referred to as "cushion body"), and at the same time adhering the skin. The present invention relates to an integrally molded body.

Conventionally, urethane foam was mainly used as a cushion body, but since urethane foam changes significantly over time due to thermal deterioration, it had to be manufactured with a hard texture. There were disadvantages such as feeling depressed, feeling like you had hit rock bottom, and being disliked.

The present inventors previously identified and proposed a polyester fiber cushioning material that eliminates these drawbacks and exhibits excellent performance while eliminating these drawbacks in Japanese Patent Application Laid-Open No. 58-31150. We conducted research to produce seats suitable for vehicles and general furniture at low cost by simultaneously performing heat molding and adhesion of the skin.

Conventionally, seat bodies have been extremely time-consuming, so a vacuum forming method has been provided in which urethane or the like is foamed within a bag-shaped skin to form a cushion body. This method has the following disadvantages: (1) a breathable skin cannot be used; and (2) it is difficult to repair a large space inside the urethane or a large space between the skin and the urethane.

In recent years, there has been an increasing demand for sheet breathability, a soft feel for the skin, a luxurious feel, etc., and products and manufacturing methods that meet these demands have been proposed.

Namely, Japanese Patent Publication No. 56-17087, Japanese Unexamined Patent Publication No. 1983
This is disclosed in Japanese Patent Application Laid-open No. 17087 and Japanese Patent Application Laid-Open No. 17088 (I3388), in which wadding, molding, etc. made of urethane foam etc. are sequentially applied to the skin of a bag-shaped fabric. Although this method satisfies the breathability of the seat body and the good feeling of the surface, and does not cause a deterioration in quality, it is time-consuming.

The purpose of the present invention is to eliminate such drawbacks and provide a lower body molding/body that has good breathability, soft feel, and luxurious feel without causing quality deterioration, and which is suitable for seat bodies etc. that can be manufactured at low cost. Although the present invention provides an integrally molded body, it can of course be used as a wall covering material, a sound absorbing material, etc., or as a part of a seat body.

The object of the present invention is to create a thermal adhesive fiber with a low melting point @1l-1
Synthetic FA fiber and/or non-thermally adhesive fiber having a higher IXIII point than the thermally adhesive fiber, 90~50% by weight
At least 40 in 1 of the thermoadhesive fibers are added to at least a part of a web or a laminate thereof consisting of 50%
9b-containing sheet, and by applying pressure and heating, at least a portion of the intertwined portions of synthetic fibers and/or non-thermally bondable fibers in the web are bonded, and the web and -1 This is achieved by an integrally molded body formed by adhering and integrally molding the skin.

The synthetic fibers and non-thermal adhesive fibers used in the present invention include known i-fibers, such as synthetic fibers such as polyester, polypropylene, and polyacrylic, natural fibers such as cotton, wool, and hemp, and recycled fibers such as rayon and KIEPL. Examples include fibers alone or in combination of two or more, but i
+7 Preferably synthetic fibers such as polyester and polypropylene, more preferably polyester fibers due to their excellent performance. As for polyester, ordinary polyethylene terephthalate and polyhexamethylene terephthalate are used.

Polytetramethylene prephthalate, poly 1. '/--
Dimethyl cyclohexane terephthalate, polyvivalolactone, or their copolymer esters or composite fibers made by spinning Also, the fineness is usually 1 to 50 denier, and the length is usually 30 to 11.
1507/l/'771 is 1'i good.

Thermal adhesion properties (I, fibers) (J1 Any material may be used as long as it has a melting point lower than the above-mentioned non-heat adhesive m fibers, preferably 30°C or lower, has adhesive properties, and exhibits an If form. Examples include polymerized polyester, polyolefin, polyvinyl alcohol, and more preferably copolyester.

Examples of the polyester include aromatic dicarboxylic acids such as adipic acid, sepatic acid, and naphthalene dicarboxylic acid, and/or alicyclic dicarboxylic acids such as hexahydroterephthalic acid and hexahydroisophthalic acid, and diethyl dicarboxylic acids. 1
Non-grilled 2-leur.

Aliphatic and alicyclic diols such as polyethylene glycol, propylene glycol, and baraxyline glycol J (
It is a copolymerized polyester containing a predetermined number of 1 and oxyacids such as para◆droxybenzoic acid as desired.For example, isophthalic acid and 1,6-hexanediol are added to terephthalic acid and ethylene glycol. Examples include polymerized fibers and composite fibers produced by Funshugate spinning. In addition, the fineness is usually 1 to 20 deniers, and the fiber length is usually 30 to 100 m/? It is fine if it is l'l.

The web of the present invention is 10 to 50% by weight, preferably 15% by weight.
-30% by weight of thermoadhesive fibers and 90-50. It is formed by a known Unibar method by mixing synthetic fibers and/or non-thermally adhesive fibers having a higher melting point than the thermally adhesive fibers in an amount of i%, preferably 85 to 70% by weight. If the ratio of heat-adhesive fibers is less than 10 weight percent, it will cause the production of a composite web with heat-adhesive fibers and non-thermally adhesive fibers of less than 1%.
The heat fusion between 1 and 1 is insufficient, and on the other hand, when 50% by weight occurs, there is too much fusion and becomes too hard. Within this range, by appropriately changing the mixing ratio of the fibers on both sides, the cushion body can be made to have partially different hardness. Furthermore, it is also possible to use a part of the web that has been pre-formed by applying pressure and heating.
It's Hi.

The product of the web or its laminate is o, oos to 0.
When adjusted to l 5 y/cJ, the impact resilience of the molded cushion body exhibits a suitable value.

At least 40% by weight between the web and the epidermis,
Preferably 70% by weight or more, particularly preferably 18310
A sheet containing heat-adhesive fibers of 0 MJ-a% is interposed, and the cushion body and the skin are bonded together by pressurization and heating.

Here, if the content of thermally adhesive fibers is less than 40M%, the adhesion between the cushion body and the skin will not be sufficient. By setting the ratio within this range, the cushion body and the outer skin are bonded at points, and the soft feel of the outer skin can be obtained. Further, the sheet referred to herein includes a N-Ut layer web.

The skin of the present invention may be 1:I, paper, non-woven fabric, natural skin, turquoise material, etc., directly or with some third party.
Anything that shows adhesion through the layer is fine, but
A fine fabric that is breathable and has a soft feel is suitable.
Particularly suitable is a stretchable polyester knitted fabric.

However, depending on the application, a non-breathable skin such as vinyl chloride leather may be suitably used.

The skin may be used as it is, but if it is to be adhered to at least three sides of the web, it is preferable to use a skin whose external shape has been previously formed by a known method. Especially the 5th grade
In the case of iii.4, it is preferable to form the epidermis into a bag shape in advance. In addition, when performing embossing formation, the shape may be created on the skin using an upper mold and a lower mold that can be heated in advance, but it is also possible to process a pre-integrated molded body using a mold that can be heated. It is Noh.

Molding of the cushion body of the present invention and adhesion of the skin 11 The web, sheet, and skin are sequentially pressed between parallel plates or in a mold, and heated with moist heat means such as hot water, Steam A, or high-pressure steam. However, dry heating means such as hot air may be used as the heating means, and furthermore, continuous molding between the endosys belts,
It is also possible to glue.

The integrally molded article of the present invention produced in this manner is suitable as a seat body having excellent performance as a cushion body, air permeability of the skin, a soft feel, and a luxurious feel.

Next, the present invention will be explained with reference to the drawings.

Figure 5451 shows the structure of an example of the integrally molded body of the present invention...White 1
It is shown in i1.

1 is a cushion body, 2 is a seat, 3 is an outer skin 4 is a calyx portion, and 5 is an embossed groove portion.

Although not shown in the drawings, the cushion body of the present invention has a large number of fibers intertwined three-dimensionally and irregularly, and is fixed by all of the heat-adhesive parts or by knots formed by melting the heat-adhesive parts. However, the anti-elasticity of synthetic fibers or non-thermally bondable fibers is less likely to be diminished.

The outer skin is bonded by the heat-adhesive part that forms the sheet, resulting in point adhesion, and this feel can be utilized even when the material is soft to the touch.

As shown in the perspective view of FIG. 2, the skin can be adhered as appropriate from one side of only 3a to the vertical surfaces of 3a, 3b (including opposing surfaces not shown), and 3c (same as 3b).

The embossed part and the embossed groove part shown in FIG. 1 may be omitted.

Although not shown, the cushion body can also be used as a wadding and a portion corresponding to the outer skin.

FIG. 3 shows a cross-sectional view of an example in which the skin is formed into a bag shape and embossed in advance.

Emboss formation may be performed by heating and pressing between heated upper and lower molds. Although not shown, the bead may or may not be present.

FIG. 4 shows an example using cushion bodies of different hardness.

For example, it is also possible to preform and use the cushion body in the portion indicated by lb.

Next, the present invention will be explained with reference to Example ##Shihoku Kiju.

Example 1 Fiber: polyethylene terephthalate/containing polyester (terephthalic acid/isophthalic acid = 6 g, 4O, melting point 110°C) core + Ti type, composite fiber (denier: 4 denier, fiber length: 51 m) Polyethylene terephthalate (melting point: 257°C
A fiber length of 10 denier fiber length s 1 m/m) is used. Polyethylene terephthalate class a! I, and Kyodo-containing polyester fiber were mixed at a ratio of 80:20, and a random univar (therefore, the basis weight was 200 f/n) was mixed.
? Manufacture webs.

In addition, after producing a web of co-pj 4 (polyester 9. fiber (m degree 0 denier set #l'r length 51 tn/m) using a roller card alone (;J40 y/nl), roll lii (140 ℃, ioxzo/-
G) to pre-manufacture a heat-press bonded sheet.

On the other hand, upper and lower molds made of polyester for automatic 41 seats are machine sewn into the shape of the seat cushion of the front seat, and can be heated with steam! Emboss formation was performed using the emboss to obtain a pouch-like epidermis.

Next, the bag-shaped skin was transferred to a stainless steel mold having punch holes of approximately the same shape as the lower mold described in 1iiJ, the sheet was placed therein, and the web was placed on top of the mold with a density IQ: 11.03.
Fill the mold with a bond layer to f/cl, punch holes in the mold, put the top lid on, and then put it in a double high pressure tank. After reducing the pressure inside this can to 50 +y@lIl+, it was heated to 130°C.
Forming the cushion body and adhering the skin using high-pressure steam
Do this for 0 minutes. After releasing the high-pressure steam to atmospheric pressure, the pressure inside the can was again reduced to 50 an 1 g to sufficiently reduce the moisture content. Next, air is introduced into the can to return it to atmospheric pressure, and then the mold is taken out from inside the can, and the integral molded body is taken out from the mold.

The obtained integrally molded product exhibited good impact resilience, had a 1111 temperament, had a soft feel, and had a luxurious feel, making it suitable for a seat body.

Example 2 A web and a sheet are manufactured in the same manner as in Example 1.

A bag-shaped skin obtained by sewing a raised polyester tricot product for a U-mounted 11f seat into the shape of the seat cushion portion of a front seat is placed in a stainless steel M mold with punched holes of approximately the same shape, and the web and An integrally molded body is produced using the sheet in the same manner as in Example 1.

Next, the integrally molded body was placed in a stainless steel box having embossed protrusions (3), and after the A1J was covered with a top lid, embossing was performed under the same conditions as in the case of making the integrally molded body.

The integrally molded body thus embossed is a molded body suitable for a seat body, as in Example 1. Example 3 An integrally molded body is produced in the same manner as in Example 2.

Next, an embossed convex mold that can be heated with steam is heated to 130° C., and the convex mold is pressed against the integral molded body for 3 minutes. Next, after releasing the heated steam in the convex shape to the atmosphere, 100. mnr f
At the same time as the pressure is reduced to ig, the vicinity of the convex suppression portion is cooled by blowing cold air.

After cooling to 70°C or less, the pressed convex mold was raised and the integrally molded body was removed.
And times V! The molded product was suitable for a seat body.

Example 4 In the same manner as in Example 1, polyethylene terephthalate m fibers and copolymerized polyester fibers were mixed and mixed with Rollano J-do and cross wrapper.
Produce a web of W/nl.

”: Said web, sheet between the all-steel drive endless belts with a lower gap of 20 m,/tn.

It is laminated and passed through 1ll'i of the epidermis, and heated with hot air at 180°C for 5 minutes. (herein referred to as “Implementation”))
The skin shown in Section 1 is the skin of Example 1 before being processed into a bag.

The fl; molded body was a molded body suitable for use as a skin-attached body for the seat + and p bodies.

Comparative Examples 1 to 3 Various integrally molded bodies were manufactured as shown in °+11, but
Sufficient performance was not achieved for the reasons shown in the evaluation section.

Table 1 Example 5 Same as Example 1, use web and sheet! 1xll
Build.

Polyester smooth lining for motorcycle seats Adhesive vinyl chloride leather is sewn into a double seat shape using high-frequency welgoo.

Next, an integral molded body is manufactured in the same manner as in Example 1 except that the temperature of the high temperature steam is 115°C.

The obtained integrally molded product exhibited excellent impact resilience and was suitable for use as a double seat for two-wheeled vehicles.

Actual Mli Example 6 An integral molded body is manufactured in the same manner as in Example 4 except that the skin is made of polyester smooth lining adhesive chloride peel leather for motorcycles, and the hot air heat treatment is performed at 160°C for 10 minutes.The obtained integral molded body is The molded product was suitable as a surface layer for a double seat for a two-wheeled vehicle.

Example 7 A polypropylene/polyethylene parallel type composite fiber (melting point 165°C/130°C, fineness 6 denier e-fiber length 64 m/m) was used as thermal adhesive 1a, and the sheet was made into the composite WIN
An integral molded body is manufactured in the same manner as in Example 1, except that J& is used.

The obtained integrally molded body, like Example 1, was a molded body suitable for a seat body.

Example 8 An integrally molded body is produced in the same manner as in Example 5, except that the polypropylene/polyethylene parallel type composite t' fiber is used as in Example 7, and the sheet is produced using the composite IiN fil.

As in Example 5, the obtained integrally molded body was a molded body suitable for a double seat for a two-wheeled vehicle.

[Brief explanation of drawings]

Figure 1 is a cross-sectional view of the integrally molded body, Figure 2 is a perspective view of the integrally molded body, Figure 3 is a cross-sectional view of the skin sewn into a bag shape and embossed, and Figure 4 is a cross-sectional view of the skin with different hardness. FIG. 2 is a sectional view of an integrally molded body using a cushion body. -Figure 1Figure 2

Claims (9)

[Claims] (1) Heat-adhesive fiber with low melting point 10-50 weight fit
% and 90 to 50% of synthetic fibers and/or non-thermally adhesive fibers having a higher melting point than the thermally adhesive fibers, or a laminate thereof, at least 40% of the thermally adhesive fibers are coated on at least one side of the web or a laminate thereof. % by weight, and by applying pressure and heating, at least a portion of the intertwined portions of synthetic fibers and/or non-thermally adhesive fibers in the web are bonded together, and the web and the skin are bonded together. An integrally molded body made by bonding and molding. (2) 15 to 30 weight of heat-adhesive fibers in the web]J
1% of the molded article according to claim 1. (3) Heat adhesive elk g4! The molded article according to claim 1 or 2, wherein is polyester fiber. (4) The molded article according to claim 3, wherein the polyester is a copolymerized polyester. (5) The molded article according to claim 1, wherein the synthetic fiber is a polyester fiber. (6) The content of heat-adhesive fibers in the sheet is 70% by weight.
The molded article according to claim 1, which is the above. (7) The molded article according to claim 1, wherein the skin is a knitted fabric. (8) The molded article according to claim 1 or 7, wherein the skin is a polyester woven material having elasticity. (9) The molded article according to claim 1, wherein the skin is synthetic leather. (g) A molded article as set forth in claim 7, in which the synthetic leather is made of vinyl chloride.I Claim 7, in which the outer skin is adhered to at least three sides of a web or a laminate thereof. The molded article according to claim 1. (c) The molded article according to claim 1, in which the skin is made of straw in advance. a3 The molded article in claim 1, in which the skin is pre-embossed.
The molded article described in Section 1. α→ The molded article according to claim 1, wherein a part of the web is preformed by applying pressure and heating. The density of the ao web or its tARb body is 0.005
The molded article according to claim 1, which has a particle diameter of ˜0.1517/αl.