JPS61141391A - Cushion member and its production - 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 Object of the Invention (Technical Field) The present invention relates to a cushion member and a method for manufacturing the same. More specifically, the present invention relates to a cushion member that is easy to manufacture and has good ventilation and durability for use in automobile seats and the like.

(Prior Art) Conventionally, seats used in vehicles such as automobiles are made by placing polyurethane foam on a cushioning material such as a plain weave tape made of polyethylene or polypropylene or palm rock material, and placing polyurethane foam on the cushioning material. A seat body in which the surface of the polyurethane foam is covered with a skin material and placed on a spring stretched over a frame is mainly used.

However, these seats have poor ventilation because none of the materials that make up these seats have breathability, and they are unable to dissipate body heat or heat from the outside air while sitting on the seat. It was making me feel uncomfortable inside. Further, since the cushioning material of the seat body is mainly made of polyurethane foam, if it is placed directly on the spring, the polyurethane foam will be cut at the contact surface with the spring after long-term use. For this reason, direct contact between the polyurethane foam and the spring is avoided, and cushioning materials such as palm rock material, polyethylene nonwoven fabric, and polyethylene and polypropylene Herashan cloth (plain weave) are used. However, using such a cushioning material not only increases cost but also reduces the cushioning properties, and does not provide an air dispersion effect from the lower part.

In addition, since polyurethane has lower pressure elasticity than the fiber cushioning material, it is necessary to increase the thickness of the polyurethane foam layer in order to maintain good cushioning properties. This has the drawback of increasing the vehicle body rest.

On the other hand, as a cushioning material with relatively good air permeability, a cushioning member is known in which a locking material such as synthetic m-fiber IIA is integrally bonded to at least a portion of the surface of a base made of palmrock material as a sheet surface layer. (Japanese Unexamined Patent Publication No. 1973
-101.164).

However, since the base material of this type of cushioning material is mainly palm rock material, it is heavy (and because it is hygroscopic, it not only poses problems in improving the quality of automobiles, etc., but also has problems in durability. Particularly when used for a long period of time, it has the disadvantage of causing a so-called "sagging" phenomenon, which reduces the necessary cushioning properties and hardness.Moreover,
There was a drawback that the desired air permeability could not be obtained.

The present invention was conceived by first cutting synthetic fiber filaments with three-dimensional curls into predetermined dimensions, making them into cotton, compressing them into a predetermined shape while warping them, and bonding the mutual contact points of the filaments with adhesive. The material has been found to have high impact resilience, breathability, and excellent cushioning properties (Japanese Patent Application Laid-open No. 52-152.573), and also a synthetic fiber filament aggregate with three-dimensional curls made of cotton. A cushioning material in which each contact point between the filaments of the cushioning material is bonded with an adhesive, and the curling shape of the filament of the cushioning material has a partial directionality, and various shapes are formed by expanding and contracting respectively. It has also been found that a filament locking material formed by distributing the partially tightly intertwined portions of the curled filaments according to the required load strength has an even more excellent effect. In addition, as a preforming method and manufacturing method for cushion members made of these three-dimensional curl filaments, filament y having three-dimensional curl
An aggregate of r1 fibers is supplied to a conveying device, and while the conveying device is moved, a rotary body having a large number of needle-like objects is rotated to bring the nail-like objects into contact with the short filament fiber aggregate. , the preform is preformed by scraping off a predetermined portion, and the preform is given a predetermined volume vl! It is also disclosed that compressing the preform to a certain degree, then applying an adhesive liquid to the preform, and then heating and drying the adhesive liquid is extremely erodible (JP-A-57-1999). 37.481@, JP-A-57-3
7. No. 482).

However, although these cushion members exhibit good elastic performance overall, when used for example in vehicle seats, the cushion members are placed on springs tensioned on the seat frame. The intersection points of the filaments, which were fixed by adhesive, are destroyed due to abrasion with the spring surface, and the durability of the cushion member on the so-called spring surface is insufficient. There still remains a need to avoid direct contact with the cushioning material and use it through a cushioning material such as palm rock material, polyethylene nonwoven fabric, and polyethylene and polypropylene hetsushank0s (plain weave).

Furthermore, in order to solve the problem of durability of the spring surface of such a polyester filament cushion member, the present inventors compressed and formed short polyester filament fibers having three-dimensional curls of a relatively large denier into a predetermined shape. A solid material having a denier smaller than that of the filament is placed on a comparatively hard and breathable lower filament cushion material layer, which is formed by applying an adhesive to the filament molded body obtained by bonding the filaments and their mutual contact points. An F-layer filament cushioning material layer with relatively low hardness is provided by applying an adhesive to a filament molded body obtained by compression molding curled polyester short fibers into a predetermined shape to bond the mutual contact points of the filaments. We have discovered a cushioning member that
No. 18,797, Patent Application No. 118.798/1982). This cushion member having a vi-layer structure of filament molded bodies has extremely excellent air permeability and durability.

(Problem to be solved by the invention) *q nu +“8°′″N *″′″l″J l&
! It has excellent air permeability and durability equivalent to or better than the cushion member having a 7'5'1-tont molded laminate structure, and is easier and cheaper to manufacture than the filament molded laminate structure cushion member. We strived to provide cushioning materials.

That is, an object of the present invention is to provide an improved cushion member and a method for manufacturing the same. Another object of the present invention is to provide a cushion member that has good air permeability and durability and is easy to manufacture, and a method for manufacturing the same.

Structure of the Invention (Means for Solving Problems) The above objects are to compress and mold polyester filament 'ti41A fibers having three-dimensional curls into a predetermined shape, apply an adhesive to a filament molded body, and apply an adhesive to the filament. A filament cushion member formed by bonding mutual contact points, characterized in that more adhesive is attached to the bottom part of the cushion member than other parts, thereby increasing the strength of the bottom part. Achieved by members.

The present invention also provides that the bulk density of the bottom portion of the cushion member is 0.
The cushion member has a bulk density of 0.02 to 0.30 J/cm3 and a bulk density of 0.01 to 0.2+J/cm3 in other parts. Furthermore, in the present invention, the polyester filament has a thickness of 50 to 2 as a monofilament.
,000 denier.

The above objects further include producing a filament cushion member by applying an adhesive to a filament molded body obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape to bond mutual contact points of the filaments. In the method, when applying an adhesive to a filament molded body, consciously apply more adhesive to the bottom part of the filament molded body than other parts, and cure the adhesive while maintaining this state. This is achieved by a method of manufacturing a cushion member characterized by the following.

The present invention also provides a method in which, when applying an IBW agent to a filament molded body, the bottom part of the filament molded body is kept downward with respect to the vehicle force direction, and the ridges, T, and drops of the adhesive cause contact with the bottom part of the filament molded body. This shows a method of manufacturing a shoe-contact member in which a large amount of adhesive is applied to the bottom surface of a filament molded body by moving the filament from other parts. The present invention further provides that the adhesive adhesion time to the bottom part is 50 to 500 (1/10
This figure shows a method of manufacturing a cushion member in which 0 g filament is attached with adhesive to other parts, and ffff1 is 10 to 300 a/1009 filament.

(Function) Therefore, the cushion member of the present invention is characterized in that the strength of only the bottom portion of the polyester filament cushion member is increased by using an adhesive for joining the contact points between the filaments. In other words, by applying more adhesive to the bottom part than to other parts, the filaments near the bottom, which is the so-called spring surface, are bonded with a large amount of adhesive to form a strong hardened layer, and the frame, spring Even when placed on top, it functions as an effective spring receiving material.On the other hand, the square part is no different from conventional polyester filament cushioning members, so it has excellent breathability and cushioning properties. It has excellent performance. In addition, in this manufacturing method of the cushion member, when applying adhesive to join the contact points between the filaments of the filament molded body, the adhesive is intentionally applied to the bottom surface of the filament molded body more than other parts. 'j is sufficient, and the above-mentioned cured layer can be obtained in the same manner as the molding of the cushion member without requiring any separate members, making it very easy and inexpensive for the first time.

(Detailed description of the invention) Hereinafter, the present invention will be explained in more detail based on the drawings.

The cushion member 1 of the present invention is made by compression-molding polyester filament short fibers having three-dimensional curls into a predetermined shape, applying an adhesive to a filament molded body to connect the contact points of the filaments, and then As shown in Figure 1, more adhesive is attached to the bottom part of the cushion member than other parts, forming a kind of hardened layer 2, while the other parts are covered with a cushioning layer 3 with good air permeability.
1' is formed.

The polyester filament used in the cushion member of the present invention is a monofilament of 50 to 2
．． 000 denier, preferably 10C to 1.000 denier, most preferably 150 to 800 denier, and having three-dimensional curl. Here, the three-dimensional curl means a three-dimensional curl in a broad sense such as bidirectional curl and three-directional curl, but preferably a three-dimensional three-dimensional curl filament, for example, published in Japanese Patent Application Laid-Open No. 52-14 by the same inventor.
4,448@The method disclosed in the publication and 'JA'
Double twisted filament D as shown in Figure 10 by a.
The 11th
A tridirectional three-dimensional curl filament F as shown in the figure is obtained. The length of filament after cotton production is 25~2001
11 m is preferred. Thus, portions of the filament coil at section a over section b, and section C coil over section d. However, the part of e is f
Instead of coiling over the section, coil it under it. Thus, sections of filament from e to d are in two entanglements or coils of the helix.

This is correctly called a non-directional helix, and when one coil becomes non-directional with respect to the other, it looks very similar to a V-shaped telephone cord when something goes wrong. .

The bulk density of the hardened layer 2 of the cushion member 1 of the present invention is 0.0
2-0.3g/cm3, preferably 0.05-0.
2fJ/cm3, while the bulk density of the cushion layer 3 is 0.01 to 0.2(]/cm3, preferably 0
．． 02 to 0.1 g/cm3. Okono hardening layer 2
The difference in the bulkiness of the cushion layer 3 and the cushioning layer 3 is
This is due to the difference in the bulk density of the hardened layer 2, which is 0.02g.
If it is less than 0.4 g/cm3, the durability of the bottom part where the hardened layer 2 is made may be insufficient when placed on a seat frame or spring.
If it exceeds 3, the air permeability may be inhibited, so both are unfavorable.

In the cushion member 1 of the present invention, the adhesive for bonding the filaments and their mutual contact points includes synthetic rubber such as styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, urethane rubber, natural rubber, vinyl adhesive, and acetic acid. Vinyl adhesives, cellulose acetate adhesives, acrylic adhesives, etc.

The cushion member 1 configured as described above is manufactured as follows. However, for example, JP-A [57-3]
As described in No. 7,481, an aggregate of polyester filament short fibers having three-dimensional curls as described above is supplied to a conveying device, and while the m-feeding device is moved, a large number of needle-like objects are erected. A filament molded body is preformed by rotating a rotating body to bring the nail-like object into contact with the short filament fiber aggregate and scraping off a predetermined portion. The thus preformed filament molded body is then compressed by an endless belt and/or roller or other means as shown in JP-A-57-211,387 to form a filament molded body having a predetermined bulk density. If necessary, this molded body is needled with a needle equipped with a barb to achieve a predetermined needle density (or rubbed to improve compression moldability 1').
. In this way, a filament molded body 4 having a predetermined shape as shown in FIG. 2 is molded. Next, the adhesive 6 as described above is applied to the filament molded body 4 in the form of a solution or latex by a spray method as shown in FIG. 3a or a dipping method as shown in FIG. 3b. Note that the dipping method is preferable to the spraying method because the yield of the adhesive 6 is better and the amount of adhesive applied can be set arbitrarily. At this time, in order to apply more adhesive 6 to the bottom surface part 5 of the filament molded body 4 than to other parts, it is necessary to apply adhesive liquid to only the bottom surface part 5 again by spraying or dipping, or to When applying the adhesive 6 to the bottom surface, keep the bottom surface portion 5 downward with respect to the direction of gravity G. That is, normally, the adhesive liquid is applied by spraying or dipping with the bottom surface portion 5 facing down. The adhesive 6 which has adhered to other parts above the part 5 in an excessive amount is moved by 1' to the bottom part 5 by falling under its own weight. Therefore, the bottom surface portion 5 of the filament molded body 4, that is, the hardened B2
The adhesive is attached to the parts constituting the dry weight of 50 to 500 g/100 g filament, preferably 80 to 4000/100 (1 filament,
On the other hand, other parts, namely cushion I! ! ! ! The time required for adhesive to adhere to the parts constituting part 3 is 10 to 10% in terms of dry weight.
300 (+ /100 (+ - filament, preferably 30 to 200 + j /100!; l - filament. Figure 8a shows the state of adhesion of the adhesive at the bottom part, and Figure 8b shows the other parts. Fig. 5a schematically shows the state of adhesion of the adhesive in Fig. 5a. As shown, the adhesive 5 is placed on an endless belt 7 running in a substantially horizontal direction, and cured in a drying oven 8 using hot air, infrared rays, high frequency, etc. For example, 1, and 80 to 2 when hot air is used.
It is heated and dried at 00°C, preferably 10°C to 160°C, for about 10 to 60 minutes, preferably 15 to 40 minutes. Thereafter, in order to form the filament cushion member 1 into a predetermined shape, it is inserted into a sea urchin mold 9 shown in FIG. To remove moisture, the mixture is heated and dried again as shown in FIG.

As another case eA, after draining the adhesive liquid as shown in Fig. 4, the filament molded body 4 is placed in the mold 9 and processed in the drying oven 8 as shown in Fig. 5b. By drying with sulfur, a cushion member 1 having a desired shape can be obtained. Further, if necessary, adhesive may be applied again to the filament cushion member 1 thus completed by spraying or dipping, but in this case as well, in the same way as in the process described above, the bottom surface portion 5 is It is necessary to apply the adhesive and heat dry it while keeping it below G.

Furthermore, when the adhesive is a moisture-curing adhesive, the adhesive is applied in the same manner as above, placed in a mold, and heated in the presence of water vapor, for example, at a vapor pressure of 0.2 to 5 k (J/cm2, preferably 0.5 to 3 kg/cm2 for a predetermined period of time, e.g.
The adhesive is compressed for 15 minutes, preferably 2 to 10 minutes, to be cured by moisture, and after a suitable predetermined period of time, it is removed from a mold and dried using hot air, infrared rays, or high frequency waves to remove moisture.

In the present invention, the above adhesives can be used alone or in combination, but it is even better if the filaments are first bonded to each other with a synthetic rubber adhesive and then treated with a natural rubber adhesive. The result is 14? It will be done. That is, by first bonding the contact points between the filaments with a synthetic rubber adhesive that has good selectivity for synthetic fibers, and then treating with a natural rubber adhesive,
This improves the bonding strength of the synthetic rubber adhesive, the flexibility of the cushioning material as a whole, and the hysteresis loss and compression set of the cushioning material.

On the other hand, by pre-applying a synthetic rubber adhesive, the relatively low adhesion of natural rubber adhesives to synthetic fibers is improved and increased. In this case, it is preferable that the synthetic rubber latex and the natural rubber latex have approximately the same amount of Wffi, and the synthetic rubber latex Wffl is approximately the same amount as the conventional synthetic rubber latex WM.

The cushion member 1 of the present invention obtained as described above is used as a seat body 10 with the necessary portions covered with a skin body. For example, as shown in FIG.
The surface portion 11 is covered with an air-permeable skin 13 made of woven fabric such as nylon, polyester, acrylic, or knitted fabric (preferably coarse woven fabric). On the other hand, the side part 12 and bottom part 5a of the cushion member are made of fabric, leather,
It is covered with a skin body 14 such as artificial leather. The breathable skin body 13 and the skin body 14 are joined at the peripheral edge of the surface portion 11 directly or via the beaded edge portion 15 by IN or other methods. However, the cushion member 1 of the present invention does not necessarily have to be entirely covered with the skin (in particular, the bottom portion 5.a may be used in an exposed state.) The seat body 10 as described above is It is used by being placed on the figure 8 spring j:g or other springs, belts, etc. adjusted to the seat frame 16.

Effects of the Invention As described above, the present invention involves applying an adhesive to a filament molded body obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape to bond the contact points between the filaments. This filament cushion member is characterized by having more adhesive adhered to the bottom part of the cushion member than other parts, making the bottom part stronger, which improves breathability and It is a cushioning member that has good durability and is easy to manufacture, and is suitable for use in automobile seats and the like.

The present invention also provides a filament cushion member which is obtained by compressing polyester filament staple fibers having three-dimensional curls into a predetermined shape and applying an adhesive to a filament molded body to bond the mutual contact points of the filaments. l In the 7M method, when applying adhesive to a filament molded body, consciously apply more adhesive to the bottom part of the filament molded body than to other parts, and cure the adhesive while maintaining this state. Because of this feature, the excellent cushion member described above can be provided extremely easily and at low cost without requiring any separate members or special steps.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional view of one embodiment of the cushion member of the present invention, Figs. FIG. 8b is a schematic diagram showing the state of adhesive adhesion on the bottom surface of the cushion member of the invention, FIG. 8b is a schematic diagram showing the state of adhesive adhesion on other parts of the cushion member, and FIG. 9 is a schematic diagram showing an embodiment of the cushion member of the invention. FIG. 10 is a cross-sectional view of an example seat body in an installed state, FIG. 10 is a partial perspective view of a double-twisted filament, and FIG. 11 is a front view of a three-dimensional three-dimensional curl filament. DESCRIPTION OF SYMBOLS 1... Cushion member, 2... Hardened layer, 3... Cushion layer, 4... Filament molded body, 5... Bottom surface part, 6... 1 Eleven agent. Figure 3 @4FIJ ”656a Figure 5 (a) (b) Figure 6

Claims (6)

[Claims] (1) A filament cushion member formed by applying an adhesive to a filament molded body obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape, and bonding the contact points of the filaments with each other,
A cushion member characterized in that more adhesive is attached to the bottom portion of the cushion member than other portions, thereby increasing the strength of the bottom portion. (2) The bulk density of the bottom part of the cushion member is 0.02~
0.3g/cm^3, and the bulk density of other parts is 0.0
The cushion member according to claim 1, which has a weight of 1 to 0.2 g/cm^3. (3) The cushion member according to claim 1 or 2, wherein the polyester filament has a thickness of 50 to 2,000 deniers as a monofilament. (4) A method for manufacturing a filament cushion member in which a filament molded body obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape is coated with an adhesive to bond the contact points of the filaments, When applying adhesive to the filament molded body,
A method for producing a cushion member, which comprises intentionally applying more adhesive to the bottom surface of the filament molded body than to other regions, and curing the adhesive while maintaining this state. (5) When applying adhesive to the filament molded body, keep the bottom part of the filament molded body downward in the direction of gravity, and move the adhesive to the bottom part from other parts by the adhesive falling under its own weight; 5. The manufacturing method according to claim 4, wherein more adhesive is applied to the bottom portion of the filament molded body than to other portions. (6) Claim 4, wherein the amount of adhesive applied to the bottom part of the filament molded body is 50 to 500 g/100 g of filament, and the amount of adhesive applied to other parts is 10 to 300 g/100 g of filament. Or the manufacturing method according to item 5.