JPS6149965B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a cushion pad for a seat and a method for manufacturing the same. More specifically, the present invention relates to a cushion pad for a seat used for a seat cushion or a seat bag for a seat of an automobile or a seat of furniture, etc., and a manufacturing method thereof. Regarding the method.

Conventionally, there have been cushion pads in which portions of different hardness are formed in a portion of the cushion pad in order to improve the riding comfort of seats in vehicles, etc., and as shown in FIG. An adhesive layer 3 such as a hot-melt sheet is adhered to the back side of the adhesive layer 3, and a second cushion layer 4 is formed by foam-molding a stock solution of a foamed synthetic resin material such as urethane from the other side of the adhesive layer 3. A cushion pad 1 is present, and the cushion pad 1 has a good surface feel and excellent cushioning properties.

However, when forming a portion of different hardness in a portion of the cushion pad, the work becomes complicated and work efficiency cannot be improved, and in the cushion pad 1 shown in FIG. 1, there are pinholes etc. in the adhesive layer 3. In some cases, the stock solution of the foamed synthetic resin material impregnates the first cushion layer 2 through the pinholes due to extremely high foaming pressure during foam molding of the foamed synthetic resin material, and the first cushion layer 2 is heated to improve the surface feel. This will harden the cushion layer 2 of 1.
This may result in product defects, and furthermore, in the state where the adhesive layer 3 completely covers the first cushion layer 2, it does not have air permeability, and the foaming gas generated during foam molding is caused by the foamed synthetic resin. It has the disadvantage that it remains in the material and causes cavities and cracks in the foamed synthetic resin material.

An object of the present invention is to provide a cushion pad for a seat that has a good surface feel, excellent cushioning properties, can significantly improve ride comfort performance, and is highly economical.

Another object of the present invention is to be able to reliably adhere the first cushion layer and the second cushion layer without using an adhesive layer, and to form the second cushion layer using a foamed synthetic resin material. The foaming gas generated during the process can be completely removed from the vent hole of the foam molding machine, and there is no risk of defects such as cavities or cracks occurring in the second cushion layer, resulting in a seat cushion pad with excellent riding comfort. The present invention provides a method for manufacturing.

2 and 3 schematically show one embodiment of a seat cushion pad according to the present invention, and this cushion pad 11 includes a front pad layer 13 made of synthetic resin, and a front pad layer 1
3, and a second cushion layer 15 made of a foamed synthetic resin material formed by foaming on the lower surface of the first cushion layer 12. It consists of

The felt layer 14 is formed by mixing miscellaneous fibers such as coarse wool with semi-wool products of thermoplastic fibers such as polypropylene fibers and polyethylene fibers, and the thermoplastic fibers mixed into the felt layer 14 are heated and melted. The felt layer 14 is tightly bound and is formed into a predetermined shape by cold pressing to give the felt layer 14 appropriate hardness and cushioning properties.
is granted to.

The front pad layer 13 and the felt layer 14 can be formed independently of each other and then bonded to form the first cushion layer 12, and when the felt layer 14 is cold pressed, the The first cushion layer 12 can also be formed by laminating the front pad layer 13 and the felt layer 14 and pressing them together.

A second cushion layer 15 is formed by foam-molding a foamed synthetic resin material on the lower surface of the first cushion layer 12, and a stock solution 15' of this foamed synthetic resin material forms a felt layer constituting the first cushion layer 12. 1
An impregnated layer 14a is formed by impregnating the lower surface of the felt layer 14, and this impregnating layer 14a further hardens the felt layer 14 and improves the hardness, shape retention and cushioning properties of the felt layer 14. .

The above is the configuration of one embodiment of the seat cushion pad according to the present invention. According to the desired configuration, the cushion pad 11 uses the felt layer 14 made of inexpensive miscellaneous fibers such as coarse wool, which saves resources. It is excellent in economical efficiency, and the felt layer 14 is strongly bound by the thermoplastic fibers mixed in the felt layer 14, and the felt layer 14 is given appropriate hardness and cushioning properties. Furthermore, when molding the second cushion layer 15, there is no possibility that the surface-side pad layer 13 of the first cushion layer 12 will be impregnated with the stock solution of the foamed synthetic resin material, and a cushion pad 11 with a good surface feel can be obtained. Moreover, the impregnated layer 14a formed on the lower surface of the felt layer 14 of the first cushion layer 12, together with the thermoplastic fibers, imparts appropriate hardness and cushioning properties to the felt layer 14. Therefore, by appropriately adjusting the specifications of the front pad layer 13, felt layer 14, and second cushion layer 15, seat cushion pads 11 having various ride comforts can be obtained.

4 to 6 schematically show the steps of the manufacturing method of the cushion pad for a seat according to the present invention. First, as shown in FIG. A felt layer 14 is formed by mixing about 70% of miscellaneous fibers with 30% of thermoplastic fibers such as polypropylene fibers, using a needle method, etc., and molding a soft synthetic resin material on the upper surface of this felt layer 14. The surface-side pad layer 13 having a thickness of about 5 to 50 mm is placed on the pad layer 13, and heated by passing through a hot air circulation furnace (not shown) to heat and melt the thermoplastic fibers in the felt layer 14. The heated and melted thermoplastic fibers are firmly bound together and the front pad layer 13 and the felt layer 14 are bonded together. Incidentally, the basis weight of the felt layer is 300.
~900g/ ^m2 .

Next, the first cushion layer 12 consisting of the front pad layer 13 and the felt layer 14 is formed into a predetermined shape by performing cold pressing in the laminated state using a cold press machine (not shown). (See Figure 5).

This first cushion layer 12 is set in the upper mold 22 of the foam molding machine 21, as shown in FIG.
A vent hole 25 is formed in the upper mold 22, and the upper mold 22 is placed in a state in which the front pad layer 13 is in contact with the upper mold 22, that is, the felt layer 14 is opposed to the lower mold 23, and foam molding is performed. The stock solution 15' of foamed synthetic resin material is poured into the lower mold 23 of the machine 21, and the upper mold 22
By foam-molding with the lower mold 23 closed, it is possible to obtain a cushion pad 11 as shown in FIG. 2 in which the second cushion layer 15 is bonded to the lower surface of the first cushion layer 12.

Foaming gas generated during foam molding of the stock solution 15' of the foamed synthetic resin material and air in the mold 21 pass through the breathable felt layer 14 and the surface pad layer 13 and are formed in the upper mold 22. Since the gas is discharged to the outside through the vent hole 25, there is no risk of forming cavities or cracks in the second cushion layer 15.
In addition, the felt layer 14 has a foamed synthetic resin material undiluted solution 1.
5' is impregnated to form the impregnated layer 14a, but since the surface side pad layer 13 is not impregnated, the surface feel of the surface side pad layer 13 can be maintained in a good condition. The surface feel of the padded layer 13 can be maintained in a good condition, and the thickness of the surface-side padded layer 13, the thickness of the felt layer 14, and the amount of thermoplastic fibers mixed in the felt layer 14,
Depending on the thickness of the second cushion layer 15, etc., it is possible to obtain seat cushion pads having various different feel, hardness and cushioning properties.

The above is an outline of one embodiment of the seat cushion pad and its manufacturing method according to the present invention. According to such a structure and method, it is possible to have a good surface feel, excellent cushioning properties, and significantly improve ride comfort performance. It is economical because it uses an inexpensive felt layer, and the first cushion layer and the second cushion layer can be reliably bonded without using an adhesive layer such as hot melt. Since the first cushion layer is formed of a breathable felt layer and a surface pad layer, foam molding is easy and the second cushion layer is free from defects such as cavities and cracks. A cushion pad and a manufacturing method thereof can be obtained.

[Brief explanation of the drawing]

FIG. 1 is an explanatory cross-sectional view showing a conventional cushion pad, FIGS. 2 and 3 are explanatory cross-sectional views and partially enlarged cross-sectional views showing an outline of one embodiment of the cushion pad for a seat according to the present invention, and FIG. 6 to 6 are cross-sectional explanatory views showing each step of an embodiment of the method for manufacturing a cushion pad for a seat according to the present invention. In the figure, 11... cushion pad, 12... first cushion layer, 13... surface side pad layer, 1
4...Felt layer, 14a... Impregnated layer, 15...
Second cushion layer, 15'... Stock solution of foamed synthetic resin material, 21... Foam molding machine, 22... Upper mold, 2
3...lower mold, 25...vent hole.

Claims (1)

[Scope of Claims] 1. A first cushion layer formed into a predetermined shape, and a second cushion layer made of a foamed synthetic resin material bonded to the lower surface side of the first cushion layer, The first cushion layer is composed of a front padded layer and a felt layer bonded to the lower surface of the front padded layer, and the felt layer is formed by mixing miscellaneous fibers such as coarse hair with a semi-wool product of thermoplastic fiber. A cushion pad for a seat, characterized in that the thermoplastic fibers impart appropriate hardness and cushioning properties to the felt layer. 2. An impregnated layer is formed by impregnating the side of the felt layer to which the second cushion layer is bonded with a stock solution of a foamed synthetic resin forming the second cushion layer, and the impregnated layer A cushion pad for a seat according to claim 1, wherein the layer has appropriate hardness and cushioning properties. 3. A step of mixing thermoplastic fibers into miscellaneous fibers such as coarse hair to form a felt layer, a step of laminating a surface pad layer on one side of the felt layer, and a step of heating the felt layer to release the heat in the felt layer. A first cushion layer is formed by heating and melting the plastic fibers, and cold-pressing the heated felt layer to impart appropriate hardness and cushioning properties to the felt layer, and Set the first cushion layer in the mold of the foam molding machine,
A stock solution of a foamed synthetic resin material is injected into a mold of the foam molding machine to foam-mold the foamed synthetic resin material, and a second cushion layer is formed in a state where it is bonded to the felt layer of the first cushion layer. A method of manufacturing a cushion pad for a seat. 4. The first cushion layer is set in the upper mold of a foam molding machine, and foaming gas generated during foam molding of the foamed synthetic resin material is discharged through the first cushion layer. A method for manufacturing a cushion pad for a seat according to claim 3, characterized in that: