JPS61279281A - Cushion body 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 [Technical Field of the Invention] The present invention relates to a cushion body used for vehicle seats, bedding, furniture, etc., and a manufacturing method thereof.

[Conventional technology]

Conventionally, various materials have been used for cushion bodies. For example, synthetic resin foams such as palm rock and urethane foam made of coconut fibers have been used, and cushion bodies made of natural fibers or organic synthetic fibers such as cotton have been proposed.

Also, as a type of cushion body made of synthetic cotton,
Mix polyester fibers with low melting point binder fibers, pack them into a mold, blow hot air above the melting point of the binder fibers to melt the binder fibers, and then cool to solidify the binder, allowing the polyester fibers to bond with each other. Some are glued together.

[Problem that the invention seeks to solve]

However, all of these conventional products have drawbacks.

For example, urethane foam has poor breathability and can easily get stuffy.
There are some issues with the ride comfort. Additionally, the use of toxic substances such as amine compounds and toluene diisocyanate creates a poor working environment during production. Moreover, some produce toxic gases when burned. Currently, high-resilience urethane foam (HR foam) is said to provide the best ride comfort.
However, this has the disadvantage that it has a considerably higher density than general urethane foam.

In addition, palm rock has a large specific gravity, easily sag, and has problems with the stability of raw material supply.

Cotton, which is made of organic synthetic fibers or natural fibers, has a large settiness and is expensive, and it takes time and effort to integrally mold embedded parts such as frame lines. Furthermore, cushion bodies made of synthetic fibers with a high melting point and binder fibers with a low melting point are expensive due to poor productivity, and have the disadvantage of being weak against high heat and prone to sagging.

[Means for solving problems]

The cushion body of the present invention includes a sheet-like material in which fibers are three-dimensionally intertwined and 114M bonded to each other with a binder. It is characterized by being filled with a fiber aggregate in which the fibers are three-dimensionally intertwined and bonded to each other with a binder.

As the binder, a urethane binder having an NCO group at the end is suitable.

In the cushion body, am of lllff1 aggregates intertwined in a cotton-like manner are oriented in all directions and bonded by a binder, so that it is resistant to deterioration and has excellent breathability. In addition, since it has greater hardness per specific gravity than palm rock, urethane foam, etc., a lightweight cushion body can be obtained.

The method of the present invention also includes a step of applying a shape by laying a sheet-like material in which fibers are three-dimensionally entangled and impregnated with a binder on the inner surface of a mold by suction, and The present invention is characterized by comprising the steps of packing the aggregate inside the sheet-like object, and curing the binder in a mold. The above-mentioned fibers may be only organic synthetic fibers such as polyester, but may contain inorganic fibers such as metal or glass as necessary.

According to the method of the present invention, almost no pressure is applied to the mold, so reinforcement of the mold is unnecessary or only slight, and a simple mold with air permeability such as wire mesh or punched metal can also be used. Therefore, the mold is simple, lightweight, and inexpensive.

Moreover, in the method of the present invention, a sheet-like material made of a fiber aggregate to which a binder is attached is spread on the inner surface of a mold by suction to impart a shape, so that it can be efficiently set in a mold.

[Example 1] Polyester cotton (Toyobo, trade name Varnishup 6dX64
m+, hollow conchute type) is sufficiently opened using a fiber opening machine, and the thickness is 10 to 40 mm. Make a sheet-like product. Also, a plurality of block-shaped fiber aggregates are made using a similar Il cloth. Note that the hollow consuit type is made by crimping two types of polyester having different heat shrinkage rates, and is hollow inside. However, solid type fibers may also be used.

In the above sheet-like and block-like lIrM aggregates,
Urethane prepolymer (Mitsui Nisso Urethane.

N00%- synthesized from M N 3050 and T-80
5±0.2%)/triclene solution (prepolymer concentration 1-7wt%).

The solution is removed to a predetermined amount by centrifugal force.

The centrifugal force is 50~? 000m/See 2, and the weight ratio of cotton to urethane is about 9:1 to 5:5.

Thereafter, the sheet-like material 2 is placed on top of the mold 1 as illustrated in FIG. 1, and a blower 3 is used as shown in FIG.
Alternatively, the sheet-like material 2 is sucked by a vacuum pump, and the mold 1 is
The shape of mold 1 is given by laying it on the inner surface of the mold. In this case, the sheet-like material 2 is cut in advance to a size that is continuous across the front surface side (lower side in the drawing) and side surface of the cushion body.

Next, as shown in FIG. 3, the plurality of block-shaped m-fiber aggregates 5 are placed on the inner surface of the sheet-like material 2, and compressed and vibrated by the pressure plate 7 from the upper part of the mold 1. Make sure that the void in mold 1 is sufficiently filled with polyester cotton. Then mold 1 is closed.

The sheet-like material 2 and the fiber aggregate 5 packed in the mold 1 are blown with water vapor of 80 to 130°C in an amount equivalent to NGO or more, and after being cured with water vapor for 3 minutes, the cushion body is formed by removing the mold. obtain. FIG. 5 shows a flowchart of the above manufacturing process.

[Example 2] The same polyester cotton as in Example 1 was sufficiently opened at [1181], and then a sheet-like product having a thickness of about 10 to 401 was made. Also, using similar fibers, the individual weight is about 0.0
Create multiple spherical al*ti aggregates weighing 2-1.0 g.

The above sheet-like and spherical fiber aggregates are impregnated with an excessive amount of the same urethane prepolymer/triclene solution as in Example 1, and the solution is removed by centrifugal force to a predetermined amount.

Thereafter, the sheet-like material 2 is placed on the mold 1 as shown in FIG. 4, and the shape of the mold 1 is given to the sheet-like material 2 by suction force. Then, a large number of the above-mentioned spherical cloth aggregates 5' are stuffed inside the sheet-like material 2. In this case, the spherical rltN aggregate 5
' may be packed into the mold 1 by air flow.

Next, compression and vibration are applied by the pressure plate 7 so that the voids in the mold 1 are sufficiently filled with polyester cotton. By compressing while applying vibration in this manner, the degree of entanglement of each spherical fiber aggregate 5' can be increased. Then mold 1 is closed.

The sheet-like material 2 and the fiber aggregate 5' packed in the mold 1 are blown with water vapor of 80 to 130°C in an amount equivalent to NGO or more, and after being cured with water vapor for 3 minutes, the cushion is formed by removing the mold. was gotten. FIG. 5 shows a flowchart of the above manufacturing process.

[Example 3] Using polyester cotton having the same material and shape as in Examples 1 and 2, a sheet-like object and a block-like or spherical fiber aggregate are made. These polyester cottons are impregnated with the same urethane prepolymer/triclene solution as in Example 1.2, and the solution is removed by centrifugal force.

An upper mold and a lower mold are prepared, and the sheet-like polyester cotton is placed on both the upper mold and the lower mold, respectively, and the shape of the mold is given by the suction force of a floor or a vacuum pump. These two sheet-like materials are cut to a size that allows them to cover both the front and back surfaces and sides of the cushion body.

Then, as in Examples 1 and 2, block-shaped or small spherical fiber aggregates are stuffed inside the sheet-like material, the mold is closed, and the binder is cured and molded.

According to this Example 3, a cushion body whose entire circumference is covered with two sheet-like materials can be obtained.

(Example 4) Embedded members such as metal frame lines, suspension lines, and springs are set in the mold as necessary.Same as in Example 1, a sheet of polyester impregnated with urethane prepolymer is Cotton is placed in a mold, and the shape of the mold is given by suction force, and a block-shaped or spherical fiber aggregate impregnated with urethane prepolymer is packed into a punching metal mold and cured by steam. In the case of this embodiment, after the sheet-like material is placed in a mold and given a shape by suction, embedded members such as hanging wires may be set in the mold.

According to this fourth embodiment, it is possible to easily obtain a cushion body in which embedded members such as a frame line and a hanging line are integrated.

In addition, polyester cotton has a fineness of 1 to 50 d (denier),
A fiber length of 25 to 150 ml and a number of crimps of 3 to 25/inch can be used. Further, a spherical fiber aggregate may be formed by a mixture of inorganic fibers and organic synthetic fibers, or a spherical fiber aggregate made only of inorganic fibers and a spherical van aggregate made only of organic synthetic fibers may be mixed. May be used.

The urethane prepolymer has a functional group number of 2.5 to 8, a molecular weight (per OH) of 200 to 2,500, an EO (ethylene oxide) addition amount of θ to 20 wt%, and a terminal NGO of 2 to 30.
% can be used. Further, the solvent is a halogenated hydrocarbon such as trichlene. Other solvents are flammable and difficult to use. As the curing agent, in addition to hydrate, amine water, amine compounds, compounds containing active hydrogen such as hydroxyl groups, etc. can be used.

Both the lower mold and the upper mold are breathable molds such as wire mesh or punched metal, and the curing time can be shortened by blowing steam from the outside of the mold.

In the cushion bodies obtained in each of the above examples, the polyester fibers of the fiber aggregate are three-dimensionally entangled with each other, and the surface of li is coated with a urethane resin binder, and the fibers are coated at the intersections of lin. They are glued together with a binder. Moreover, at least one of the front and back surfaces and side surfaces of the cushion body are covered with sheet-like polyester cotton, and the fibers of this sheet-like material are also bonded to each other with a binder. Each fiber is oriented randomly in all directions. Urethane binders have strong adhesive strength and excellent heat resistance, and because they use water as a curing agent (crosslinking agent), they are easy to work with and are safe.

Table 1 below shows the physical properties of Examples 1 to 4 and Comparative Examples 1 to 3. Note that the details of Comparative Examples 1 to 3 will be described later. Moreover, FIG. 6 shows the relationship between density and hardness of Example 1 and Comparative Examples 1 to 3.

[Comparative Example 1] A polyether polyol with a molecular weight of 3000 and a functional group number of 3 and toluene di-isocyanate (T-80),
A urethane raw material consisting of water as a blowing agent and other auxiliary agents is stirred with a mixing head, then poured into a temperature-controlled mold in a predetermined amount, and the mold is closed.

Thereafter, the mold was heated at 170° C. for 10 minutes (5 minutes for HR foam) to cure the urethane foam, and then removed from the mold. In addition, when adding a flame retardant, add 10 to 2 flame retardants.
Add 0 parts. (Detailed prescription examples are shown in Table 2) Table 2 (Urethane foam prescription examples) [Comparative example 2] Latex was sprayed onto a peeled palm tree, compressed to a predetermined thickness, and heated with hot air at 120°C. dry.

This is cut to a predetermined size, laminated and placed in a mold to a predetermined density. Then spray the latex again. After closing the mold, it was dried with hot air at 120° C. and removed from the mold to obtain a palm rock.

(Comparative Example 3) Low melting point binder fiber (4d, melting point 110°C) was added to polyester cotton (6d, hollow consuit) at a weight ratio of 7.
Blend and open the cotton at a ratio of 3:3 to form a sheet with a thickness of 20 mm. This is cut into a predetermined shape, laminated and placed in a mold so as to have a predetermined density. Thereafter, the low melting point binder fibers are melted with hot air having a temperature equal to or higher than the melting point of the binder 11r4.

After the low melting point binder fibers were solidified by cooling, they were removed from the mold to obtain a cushion body made of high melting point fibers and a low melting point binder.

The cushion body of the present invention is suitable for vehicle seats, but can of course also be used for furniture, bedding, etc.

〔Effect of the invention〕

According to the present invention, it is possible to obtain a cushion body that is lighter than the conventional cushion body, has breathability, is resistant to flattening, and provides a comfortable ride. Moreover, a cushion body with good appearance, particularly good surface condition, can be obtained. Moreover, manufacturing equipment, molds, and work processes are simple, and a cushion body in which the embedded member is integrally molded can be efficiently manufactured.

[Brief explanation of the drawing]

1 to 3 are schematic diagrams showing a part of the process according to one embodiment of the present invention in order of process, FIG. 4 is a schematic diagram showing a part of the process according to another embodiment of the present invention, and FIG. The figure is a process explanatory diagram showing an example of the method of the present invention, and FIG. 6 is a diagram showing the relationship between the density and hardness of the cushion body. DESCRIPTION OF SYMBOLS 1... Mold, 2... Sheet-like object, 5... Block-shaped fiber aggregate, 5'... Spherical fiber aggregate, 7...
Pressure plate. Applicant's agent Patent attorney Takehiko Suzue Figure 6

Claims (4)

[Claims] (1) A sheet-like material in which fibers are intertwined three-dimensionally and bonded together with a binder is provided continuously over at least one of the front and back surfaces and side surfaces of the cushion body, and the inside of this sheet-like material is A cushion body characterized by being filled with a fiber aggregate in which fibers are intertwined three-dimensionally and bonded to each other with a binder. (2) A step in which a sheet material in which fibers are intertwined in a three-dimensional manner and impregnated with a binder is laid on the inner surface of a mold by suction to give it a shape; A method for manufacturing a cushion body, comprising the steps of filling the inside of the sheet-like object and curing the binder in a mold. (3) A method for manufacturing a cushion body according to claim 2, characterized in that after the fiber aggregate is stuffed inside the sheet-like object, the fiber aggregate is compressed using a pressure plate. . (4) The method for manufacturing a cushion body according to claim 3, characterized in that the fiber aggregate is compressed while applying vibration to the pressure plate.