KR20140008752A - Car seat and maufacturing method thereof - Google Patents

Car seat and maufacturing method thereof Download PDF

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Publication number
KR20140008752A
KR20140008752A KR1020120075758A KR20120075758A KR20140008752A KR 20140008752 A KR20140008752 A KR 20140008752A KR 1020120075758 A KR1020120075758 A KR 1020120075758A KR 20120075758 A KR20120075758 A KR 20120075758A KR 20140008752 A KR20140008752 A KR 20140008752A
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KR
South Korea
Prior art keywords
seat
nonwoven fabric
polyurethane sponge
molding material
foam pad
Prior art date
Application number
KR1020120075758A
Other languages
Korean (ko)
Inventor
백철균
임용상
Original Assignee
백철균
임용상
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 백철균, 임용상 filed Critical 백철균
Priority to KR1020120075758A priority Critical patent/KR20140008752A/en
Publication of KR20140008752A publication Critical patent/KR20140008752A/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

A car seat of the present invention comprises a seat frame, a seat foam pad mounted on the seat frame, and a composite molding material which is arranged between the seat frame and the seat foam pad, and is made of a polyurethane sponge and non-woven fabric, wherein the polyurethane sponge is attached to the seat foam pad and the non-woven fabric is arranged on the seat frame.

Description

Car seat and its manufacturing method {car seat and maufacturing method

The present invention relates to a seat and a manufacturing method thereof, and more particularly to a car seat and a manufacturing method thereof.

Automobiles are being upgraded to meet consumer needs. Accordingly, automobiles are applying various electronic technologies, and automobile seats are also being advanced in order to use cars more comfortably.

The car seat should not generate noise when the user seats tens of thousands of times, and should not generate noise even when the car moves. By the way, the user seated inside the car, or while the car is driving a lot of noise generated in the car seat, this noise is required to improve a lot to significantly lower the quality of the car.

Accordingly, an object of the present invention is to provide a car seat that can prevent a user from seating inside a car or generating noise while the car is running.

In addition, another problem to be solved by the present invention is to provide a manufacturing method suitable for manufacturing a car seat.

In order to achieve the above technical problem, the automobile seat of the present invention is a composite of a seat frame, a seat foam pad mounted on the seat frame, and a polyurethane sponge and a nonwoven fabric positioned between the seat frame and the seat foam pad. It is made of a molding material, wherein the polyurethane sponge is attached to the seat foam pad and the nonwoven fabric may be located on the seat frame side.

In one embodiment of the present invention, the polyurethane sponge in the composite molding material may be thinner than the non-woven fabric and may have a small unit weight. In one embodiment of the present invention, the polyurethane sponge constituting the composite molded material has a density of 15Kg / m 3 to 30Kg / m 3 , it may be made of polyether or polyester.

In one embodiment of the present invention, the non-woven fabric constituting the composite molded material has a diameter of 1 to 7 denier (denier) of the fiber (fiber), the unit weight is 30 to 200 g / m 2 or less, the fiber The material may be natural fiber, synthetic fiber, recycled fiber, or specialty fiber.

In order to achieve the above technical problem, the manufacturing method of the automobile seat of the present invention comprises the steps of manufacturing a composite molding material in which the non-woven fabric and polyurethane sponge are sequentially laminated, and the non-woven fabric and polyurethane sponge to the adhesive portion of the upper body Attaching the formed composite molding material, attaching the nonwoven fabric to the adhesive part, positioning a polyurethane sponge on the lower side, supplying a foam liquid to the lower body spaced apart from the upper body, and the lower body And foaming the foam liquid supplied to the sheet foam pad, wherein the foam is suppressed from being impregnated into the composite molding material due to the polyurethane sponge when the foam liquid is foamed.

In one embodiment of the present invention, the composite molding material may be produced by the laminating method using the needle punching or adhesive to the non-woven fabric and polyurethane sponge. In one embodiment of the present invention, when the foaming liquid is foamed, the sheet foam pad and the composite molding material may be attached to each other.

The automobile seat of the present invention includes a composite molding material between the seat frame and the seat foam pad. The composite molding material may consist of a nonwoven fabric located on the seat frame side and a polyurethane sponge attached to the seat foam pad.

The automobile seat of the present invention is attached to the polyurethane foam to the seat foam pad to control the molding speed of the foam in the foaming process for manufacturing the seat foam pad to suppress the impregnation or leakage of the foam into the nonwoven fabric. Thus, the vehicle seat of the present invention can prevent or prevent impregnation of the foaming liquid in the nonwoven fabric installed on the back of the seat foam pad, thereby preventing noise generation between the seat frame and the seat foam pad when the vehicle is being driven or when a person is seated.

In addition, the composite molding material used in the automobile seat of the present invention can omit the anti-aging wax process by needle-punching a nonwoven fabric and a polyurethane sponge to add flexibility. Accordingly, the automobile seat of the present invention can maximize the shape of the back of the seat foam pad while reducing the manufacturing cost can also improve the molding quality.

In the automobile seat of the present invention, the composite molding material is naturally attached to the sheet foam pad during the foaming process so that the composite molding material may be attached to the sheet foam pad without a separate attaching process.

1 is a cross-sectional view of an automobile seat including an automobile seat foam pad according to the present invention;
2 is a cross-sectional view for explaining the composite molded material of FIG. 1,
3 is a cross-sectional view showing a single layer molding material for comparison with the composite molding material of FIG.
4 is a flowchart illustrating a method of manufacturing the composite molded material of the present invention of FIG.
5 is a flowchart for explaining a method for manufacturing a single-layer molded article of the comparative example of FIG.
6 is a cross-sectional view illustrating a method for manufacturing a seat foam pad of an automobile seat according to the present invention;
FIG. 7 is an exploded enlarged view for explaining a process of suppressing impregnation of a foam liquid in a composite molding material in the foaming process of FIG. 6.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Embodiments of the present invention are provided to more fully describe the present invention to those skilled in the art. The present invention is capable of various modifications and various forms, and specific embodiments are illustrated and described in detail in the drawings. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. Like reference numerals are used for similar elements in describing each drawing. In the accompanying drawings, the dimensions of the structures are enlarged or reduced from the actual dimensions for the sake of clarity of the present invention.

The terminology used in this application is used only to describe a specific embodiment and is not intended to limit the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this application, the terms "comprises", "having", and the like are used to specify that a feature, a number, a step, an operation, an element, a part or a combination thereof is described in the specification, But do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or combinations thereof.

Unless defined otherwise, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Terms such as those defined in commonly used dictionaries are to be interpreted as having a meaning consistent with the contextual meaning of the related art and are to be interpreted as either ideal or overly formal in the sense of the present application Do not.

1 is a cross-sectional view of an automobile seat including a vehicle seat foam pad according to the present invention, FIG. 2 is a cross-sectional view for explaining the composite molding material of FIG. 1, and FIG. 3 is a single layer for comparison with the composite molding material of FIG. 2. It is sectional drawing which shows a molding material.

Specifically, the vehicle seat 100 according to the present invention is mounted on a seat frame (10, seat frame) made of a steel structure, the seat frame 10 and a seat foam pad for giving a cushion (cushion) as a sponge foam molded body ( 12, the seat foam pad and the seat foam pad 12 may be composed of a cover 20, a cover, a protective material. The seat foam pad 12 can be configured using a polyurethane foam pad. The car seat 100 should not generate noise while a person is seated or while driving. Accordingly, in the vehicle seat 100 according to the present invention, the composite molding material 18 may be positioned between the seat frame 10 and the seat foam pad 12 to prevent noise.

The composite molding material 18 may be made of a polyurethane sponge 14 and a nonwoven fabric 16. That is, the composite molding material 18 may be formed in a two-layer structure of the polyurethane sponge 14 and the nonwoven fabric 16 as shown in the cross-sectional view of FIG. The polyurethane sponge 14 constituting the composite molding 18 is attached to the sheet foam pad 12, and the nonwoven fabric 16 constituting the composite molding 18 may be located on the seat frame 10 side. have.

The nonwoven fabric 16 constituting the composite molding 18 may be made of various fibers, such as natural fibers, synthetic fibers, recycled fibers, special fibers, and the like. Natural fibers include wool, cotton, hemp and the like, and synthetic fibers include nylon, polyester, polypropylene, and the like. The regenerated fibers include viscose rayon, acetate and the like, and the special fibers include free carbon, kevlar, chitosan and the like. In this embodiment, the nonwoven fabric 16 constituting the composite molding material 18 may be made of polyester or polypropylene as a synthetic fiber.

The nonwoven fabric 16 constituting the composite molding material 18 may be a long fiber nonwoven fabric or a short fiber nonwoven fabric. Here, the long fiber nonwoven fabric may have a diameter of 1 denier to 3 denier and a unit weight of 30 to 50 g / m 2 . The short fiber nonwoven fabric may have a unit weight of 40 to 200 g / m 2 having a diameter of 3 to greater than 7 denier having a diameter larger than that of the long fiber nonwoven and having a unit weight greater than that of the long fiber nonwoven fabric. As a result, the nonwoven fabric 16 may have a diameter of 1 denier to 7 denier and a unit weight of 30 to 200 g / m 2 .

The reason for placing the composite molding material 18 made of the polyurethane sponge 14 and the nonwoven fabric 16 between the seat foam pad 12 and the seat frame 10 is in the foaming process for forming the sheet foam pad 12. This is to improve the problem that the foaming liquid is impregnated into the composite molding material 18, that is, the foaming liquid flows out through the composite molding material 18.

In other words, the polyurethane sponge 14 attached to the sheet foam pad 12 as in the present invention is made of a urethane material such as the sheet foam pad 12, and controls the molding process speed of the foamed liquid during the foaming process to provide a nonwoven fabric ( 16) It suppresses or prevents leakage of the foamed liquid on the back side. That is, in the foaming process for the sheet foam pad 12, the foaming liquid is prevented or prevented from flowing out through the polyurethane sponge 14 attached to the sheet foam pad 12. When the foaming liquid for forming the sheet foam pad 12 is not impregnated into the composite molding material 18, the sheet foam pad 12 may be molded into a desired shape.

Here, the present inventors, through a number of experiments, the diameter or unit weight, the total weight, the thickness of the polyurethane sponge 14 and the nonwoven fabric 16 constituting the composite molding material 18 that does not leak the foam liquid during the foaming process And the ratio was optimized. Polyurethane sponge 15 constituting the composite molding material 18 of the present invention is an ester foam or ether foam, the density is 15Kg / m 3 to 30Kg / m 3 , the unit weight is composed of 20 to 150g / m 2 can do. In addition, when the polyurethane sponge 14 is composed of 10 to 30% of the total thickness of the composite molding material 18, the nonwoven fabric 16 is composed of 70% to 90% of the total thickness of the composite molding material 18, It was found that the composite molding material 18 performs faithfully without leakage of the foamed liquid.

The nonwoven fabric 16 constituting the composite molding material 18 of the present invention may be a long fiber nonwoven fabric or a short fiber nonwoven fabric as described above, and the diameter of the fiber is 1 denier or more and 7 denier or less, The unit weight may be 70 to 200 g / m 2. Accordingly, the total unit weight of the composite molding 18 may be 90 to 350 g / m 2 . In addition, the overall thickness of the composite molding material 18 may be composed of 2mm to 3mm.

On the other hand, Figure 3 shows a single layer molding material 15 made of a nonwoven fabric for comparison with the composite molding material 13 of FIG. The nonwoven fabric constituting the single layer molded material 15 of the comparative example was configured to have a fiber diameter of 15 deniers or more and a unit weight of 120 to 200 g / m 2 . The total thickness of the single layer molded material 15 was configured to 3 mm or more. In the sheet 100 as shown in FIG. 1, when the single-layer molding material 15 of FIG. 3 is inserted between the sheet foam pad 12 and the seat frame 10, the foamed liquid during the foaming process is contrary to the present invention. The single layer molding material 15 is impregnated and the sheet foam pad 12 is not molded into a desired shape.

Of course, if the foam liquid is impregnated in the single-layer molding material 15, since the sheet foam pad 12 must be manufactured again when foaming, productivity becomes very low. In particular, when the foam liquid is impregnated into the single layer molding material 15, noise is generated during driving of a vehicle or seating of a person by friction between the seat foam pad 12 and the seat frame 10, which are finally made.

As a result, the composite foam material 13 which does not impregnate the foaming liquid is attached between the seat foam pad 12 and the seat frame 10 of the automobile seat 100 of the present invention, and thus the seat foam pad 12 and the seat frame The noise between the driving of the car and the seating of the person is prevented by friction between the parts.

4 is a flowchart illustrating a method of manufacturing the composite molded material of the present invention of FIG. 2, and FIG. 5 is a flowchart illustrating a method of manufacturing the single layer molded material of the comparative example of FIG. 3.

Specifically, the composite molding material manufacturing method of the present invention is produced by laminating or needle punching the nonwoven fabric and the polyurethane sponge as shown in FIG. The composite molding material 13 of the present invention performs the following sequential manufacturing process for the nonwoven fabric.

That is, the fiber which is a raw material is prepared (step 30). The raw fiber is in the form of agglomerates, and the diameter and unit weight of the raw fiber are the same as described above. An opening process is performed in which the prepared fiber mass is spread on a roller of the nonwoven fabric manufacturing apparatus (step 32). The fibers spread through the opening process are subjected to a fiber mixing process of uniformly mixing again in the nonwoven fabric manufacturing apparatus (step 34). The fibers which have undergone the blending process are subjected to a carding process in which a plurality of yarn strands are drawn out in a flat form, that is, planarly, in a nonwoven fabric manufacturing apparatus (step 36). Through a carding process, the fibers are plate-like in plan.

Subsequently, a web foaming process of performing a process of overlapping a plurality of plate-shaped fibers, ie, fiber plates, is performed (step 38). The plurality of superposed layers of the fiber board through the web forming process are bonded to each other through the needle punching process (step 40). The needle punching process is for joining a plurality of fiberboards together, and joining the plurality of fiberboards together while moving the needles from the upper fiberboard to the lower fiberboard. Through such a manufacturing process, a nonwoven fabric is completed (step 42).

Next, a polyurethane sponge foamed to a size of 50M in length, 1400m in width and 800mm in height and cut to a thickness of 2mm to 5mm is prepared (step 44). The unit weight of the polyurethane sponge 44 is as described above. Next, a polyurethane sponge prepared in advance on the prepared nonwoven fabric is laminated and needle punched. Alternatively, the polyurethane sponge prepared in advance is attached onto the manufactured nonwoven fabric by a laminating method using an adhesive (step 46). In this way, the composite molding material which laminated | stacked the nonwoven fabric and sponge is completed (step 48).

As compared with the manufacturing process of the composite molding material as shown in FIG. 8, the manufacturing process of the nonwoven fabric constituting the single-layer molding material of the comparative example is a needle punching process (step 30) from the fiber preparation process (step 30), which is a raw material, as shown in FIG. The process is the same until 40). However, it is different that the diameter of the raw fiber of a comparative example is 15 denier or more.

In addition, the single-layer molding material of the comparative example further proceeds the dyeing step of spraying the blue paint after the needle punching step (step 50). Next, a drying step is further performed after the dyeing step (step 52). Through such a drying process, the single layer molding material of a comparative example is completed (step 54).

4 and 5, the composite molding material manufacturing process of the present invention can reduce the dyeing process and drying process to simplify the process can reduce the composite molding material manufacturing cost. In addition, the composite molding material manufacturing process of the present invention can increase the quality of the composite molding material in a simple process by laminating and needle punching the nonwoven fabric and the sponge as described above, or by manufacturing by a laminating method using an adhesive.

FIG. 6 is a cross-sectional view illustrating a method for manufacturing a seat foam pad of an automobile seat according to the present invention, and FIG. 7 illustrates a process of suppressing or preventing impregnation of a foam liquid in a composite molding material in the foaming process of FIG. 6. Is an exploded view for.

Specifically, a composite molding material in which a nonwoven fabric and a sponge are sequentially laminated is produced (step 60). Since this step has been described above, it is omitted here. The composite molding 18 is then attached to the upper body 80, such as the upper mold. The upper body 80 is attached to the adhesive portion 82, aka squeaker. The nonwoven fabric 16 of the composite molding material is attached to the adhesive part of the upper body 82, and the polyurethane sponge 14 is located below (step 62). The upper body 80 may be in the form of an upper mold or may be a metal frame.

 Subsequently, a foaming liquid, such as a polyurethane foaming liquid, is supplied to the lower body 90, such as the lower mold, which is spaced apart from the upper body 80 (step 64). Polyurethane foams include polyols, isocyanates, foaming agents, additives, stabilizers and the like. Subsequently, the foam liquid is foamed to produce a sheet foam pad (step 66). At this time, the sheet foam pad and the composite molding material 13 produced during the foaming process are attached to each other. Since the sheet foam pad and the composite molding material naturally adhere to each other at the time of foaming, a separate attachment process can be omitted, thereby improving productivity, and also improving the adhesion properties between the sheet foam pad and the composite molding material, that is, the adhesion quality. It can greatly improve.

In the foaming process, as shown in FIG. 7, the gas in the foaming liquid passes through the polyurethane sponge 14 and the nonwoven fabric 16 as shown by the arrow, but the foamed liquid is the nonwoven fabric 16 due to the polyurethane sponge 14. Impregnation or impregnation). A polyurethane sponge is attached to the sheet foam pad to control the molding speed of the foam liquid during the foaming process for producing the sheet foam pad, thereby preventing or preventing impregnation or leakage of the foam liquid on the nonwoven fabric.

According to the present invention, the foamed liquid is made of the same material as the polyurethane sponge 14, and thus, the foamed liquid can be manufactured to adjust the flowability of the foamed liquid so that the sheet foam pad can be manufactured without the unmolded portion, thereby improving the quality and productivity of the sheet foam pad. You can. The present invention can suppress the foaming liquid is impregnated into the composite molding material due to the polyurethane sponge during foaming foaming foaming shape change of the sheet foam pad. In the present invention, when the foaming liquid reacts with the polyurethane sponge 14 to produce the sheet foam pad without the unmolded portion, the amount of the foaming liquid can be reduced more than otherwise, thereby reducing the manufacturing cost of the sheet foam pad. Can be significantly lowered.

In addition, the composite molding of the present invention can omit the anti aging wax process by needle punching the nonwoven fabric and the polyurethane sponge. Accordingly, the automobile seat of the present invention can maximize the shape of the back of the seat foam pad while reducing the manufacturing cost can also improve the molding quality.

10: seat frame, 12: seat foam pad, 14: polyurethane sponge, 16: nonwoven fabric, 18: composite molding, 20: cover, 100: car seat

Claims (7)

Seat frame;
A seat foam pad mounted on the seat frame; And
It is composed of a composite molding material between the seat frame and the seat foam pad and consisting of a polyurethane sponge and a nonwoven fabric, wherein the polyurethane sponge is attached to the seat foam pad and the nonwoven fabric is located on the seat frame side. Car seat, characterized in that. The vehicle seat according to claim 1, wherein the polyurethane sponge in the composite molding material is thinner and has a smaller unit weight than the nonwoven fabric. The automobile seat according to claim 1, wherein the polyurethane sponge constituting the composite molded material has a density of 15 Kg / m 3 to 30 Kg / m 3 and is made of polyether or polyester. The method of claim 1, wherein the nonwoven fabric constituting the composite molding material has a fiber diameter of 1 denier to 7 denier or less, a unit weight of 30 to 200 g / m 2 or less, and the fiber material is natural Car seat, characterized in that the fibers, synthetic fibers, recycled fibers, or special fibers. Manufacturing a composite molding material in which a nonwoven fabric and a polyurethane sponge are sequentially laminated;
Attaching a composite molded material consisting of the nonwoven fabric and the polyurethane sponge to an adhesive portion of an upper body, attaching the nonwoven fabric to the adhesive portion, and positioning a polyurethane sponge below;
Supplying a foam liquid to the lower body spaced apart from the upper body; And
And foaming the foamed liquid supplied to the lower body to produce a sheet foam pad, wherein the foamed liquid is suppressed from impregnating into the composite molding material due to the polyurethane sponge. Method of manufacturing a car seat. The method of manufacturing a car seat according to claim 5, wherein the composite molded material is manufactured by laminating a nonwoven fabric and a polyurethane sponge using needle punching or an adhesive. The method of manufacturing an automobile seat according to claim 5, wherein the seat foam pad and the composite molding are attached to each other when the foaming liquid is foamed.
KR1020120075758A 2012-07-11 2012-07-11 Car seat and maufacturing method thereof KR20140008752A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20160071867A (en) 2014-12-12 2016-06-22 광명산업(주) Seat using different material form

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20160071867A (en) 2014-12-12 2016-06-22 광명산업(주) Seat using different material form

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