WO2017047339A1

WO2017047339A1 - Composite cushion body

Info

Publication number: WO2017047339A1
Application number: PCT/JP2016/074602
Authority: WO
Inventors: 弘孝原田; 拓也長瀬
Original assignee: 東洋紡株式会社
Priority date: 2015-09-18
Filing date: 2016-08-24
Publication date: 2017-03-23
Also published as: JP2017056126A

Abstract

The present invention provides a composite cushion body which exhibits little bottoming out feeling while being lighter than conventional polyurethane foam units. This composite cushion body for use in vehicles is characterized in that a polyurethane foam container is filled with an elastic body which has a lower apparent density than the polyurethane foam and at least a part of which is covered with a covering material. Furthermore, in the present invention, the elastic body is preferably a three dimensional mesh-like cushion body formed from fibers, a plastic foam, a non-woven fabric or hard cotton.

Description

Composite cushion body

The present invention relates to a composite cushion body used for a vehicle seat or the like, and more particularly, to a composite cushion body that is lighter than a conventional composite cushion body and has a feeling of bottoming.

Conventionally, polyurethane foam has been employed as a composite cushion body in seats for vehicles such as automobiles and aircraft. The weight of polyurethane mounted on a single passenger car occupies a very large weight of about 8kg to 15kg. Especially in railways, ships and airplanes with many seats, the weight of polyurethane is even greater. Yes.

By the way, in recent years, low fuel consumption is required as an important value for vehicles such as automobiles. When the weight of the vehicle body increases, the fuel efficiency becomes worse. Therefore, in order to achieve lower fuel consumption than in the past, such vehicle applications have been made lighter than ever. In connection with this, the weight reduction is requested | required also for the cushion body used for the seat for vehicles as an object of weight reduction.

In order to reduce the weight of polyurethane for seats, there is a method of reducing the apparent density of polyurethane. However, simply reducing the apparent density of polyurethane makes it difficult to maintain the seat hardness that should be provided, making the seating comfort of the user the same as before weight reduction, There has been a problem that it is difficult to reduce the feeling of sticking.

In addition, as in Patent Document 1, the composite cushion body of the seat has been replaced with a net member, but this also has insufficient safety and cushioning properties compared to conventional polyurethane foam seats, and is widely put into practical use. It has not been done.

Japanese Patent Laid-Open No. 2003-127739

Under such circumstances, an object of the present invention is to provide a composite cushioning body that is lighter than a conventional polyurethane foam and has less bottoming feeling.

As a result of intensive research in order to solve the above problems, the inventors of the present invention formed a container with polyurethane foam and housed therein an elastic body having an apparent density lower than that of polyurethane foam. The inventors have found that both weight reduction and reduction in bottoming can be achieved, and the present invention has been completed.

That is, the composite cushion body according to the present invention has the gist in the following points.
[1] A composite cushion body for vehicles, wherein an elastic body having an apparent density lower than that of the polyurethane foam and at least partially covered with a covering material is accommodated in a polyurethane foam container.
[2] The composite cushion body for a vehicle according to [1], wherein the elastic body is a three-dimensional network cushion body formed of fibers, a foamed plastic, a nonwoven fabric, or hard cotton.
[3] The composite cushion body for vehicles according to [1] or [2], wherein the elastic body is a three-dimensional mesh cushion body formed of fibers.
[4] The apparent density of the container is 25 kg / m ³ or more and 200 kg / m ³ or less, and the apparent density of the elastic body is 20 kg / m ³ or more and 200 kg / m ³ or less. Composite cushion body for vehicles.
[5] The composite cushion for a vehicle according to [1] to [4], wherein the container has a bottom portion and a side wall.
[6] The composite cushion for a vehicle according to [1] to [5], wherein the side wall has a thickness of 10 mm or more.
[7] The elastic body is set in the mold in advance, and after the foaming raw material is injected into the mold, the mold is closed, the raw material is foamed and the inside of the mold is filled, and the elastic body is placed inside the polyurethane foam. The composite cushion body for a vehicle according to any one of [1] to [6], wherein the composite cushion body is molded so as to be embedded.
[8] The vehicle composite cushion according to any one of [1] to [7], wherein the container has an opening.
[9] The vehicle composite cushion according to any one of [1] to [8], wherein at least a part of the covering material is a film, a nonwoven fabric, or a woven fabric.
[10] The vehicle composite cushion according to any one of [1] to [9], wherein a volume occupation ratio of the elastic body in the composite cushion is 5% or more.

According to the present invention, a polyurethane foam and an elastic body having an apparent density lower than that of the polyurethane foam are combined, and the elastic body at least partially covered with a coating material is accommodated in a container of the polyurethane foam. A composite cushion that is lighter than before can be obtained. In addition, by accommodating the elastic body in a polyurethane foam container, it is possible to restrict the inflow and outflow of air held in the container, and thereby, a composite cushion body with less bottom feeling can be obtained by the viscoelasticity and damping effect of air. Provided.

FIG. 3 is a schematic perspective view showing a preferred embodiment of the composite cushion body of the present invention (Examples 1 to 3). FIG. 2 is a schematic cross-sectional view taken along the line II-II shown in FIG. FIG. 3 is a schematic sectional view taken along the line III-III shown in FIG. 1. 5 is a schematic perspective view of a composite cushion body produced in Comparative Example 1. FIG. FIG. 5 is a schematic cross-sectional view taken along the line VV shown in FIG. 4. FIG. 5 is a schematic cross-sectional view taken along the line VI-VI shown in FIG. 4. FIG. 9 is a schematic perspective view of a composite cushion body produced in Comparative Examples 2 to 7. FIG. 8 is a schematic cross-sectional view taken along the line VIII-VIII shown in FIG. FIG. 8 is a schematic cross-sectional view taken along the line IX-IX shown in FIG. 7.

Hereinafter, the composite cushion body according to the present invention will be described in detail with reference to the drawings showing the embodiments. However, the present invention is not limited to the illustrated examples, and can be adapted to the purpose described above and below. It is also possible to carry out by appropriately changing the range, and all of them are included in the technical scope of the present invention.

<Composite cushion body>
The composite cushion body according to the present invention is characterized in that an elastic body having an apparent density lower than that of the polyurethane foam and at least partially covered with a covering material is accommodated in a polyurethane foam container. By accommodating an elastic body having an apparent density lower than that of the polyurethane foam in the polyurethane foam container, a lighter cushion body is provided as compared with a cushion body manufactured with 100% polyurethane foam. In addition, since the elastic body at least partially covered with the covering material is accommodated in the polyurethane foam container, it is possible to restrict the inflow and outflow of air in the container, thereby making the viscoelasticity of the air and the damping effect. As a result, a composite cushion body with little bottoming is obtained.

As a method of embedding an elastic body in a polyurethane foam container, for example, an elastic body is set in a mold in advance, a foaming raw material (polyurethane foam raw material) is injected into the mold, the mold is closed, and the raw material is foamed. For example, integral foaming may be used in which the cavity of the mold is filled and an elastic body is embedded in the polyurethane foam. In the present invention, it is important to keep a certain amount of air in the polyurethane foam container and to use the viscoelasticity and damping effect of the retained air. It is preferable that the surface of the elastic body accommodated inside is not exposed to the outside as much as possible. Specifically, it is desirable that the surface of the elastic body other than the opening described later is entirely covered with a polyurethane foam container, that is, the elastic body is included in the polyurethane foam container.

In the case of integral foaming, if the polyurethane foam raw material is impregnated into the elastic body, the impregnated part has extremely high rigidity and hardness, and when used as a seat, it is too hard or causes discomfort such as the appearance of a foreign object. For this reason, it is desirable that the polyurethane foam raw material is not impregnated in the elastic body. For the above reason, when forming the container by foaming the raw material, if the elastic body is set in the mold as it is, the polyurethane foam raw material is impregnated. Therefore, in order to prevent impregnation of the polyurethane foam raw material, at least one of the elastic bodies is used. And more preferably, the entire surface of the elastic body is covered with a covering material. That is, it is essential that the elastic body is accommodated in the polyurethane foam in a state where at least a part of the elastic body is covered with a covering material.

It is preferable that at least a part of the elastic covering material is selected from a film, a nonwoven fabric, a woven fabric, and the like. These materials may be used alone or in combination. The covering material may be composed of, for example, only a film, only a non-woven fabric, or only a woven fabric, or may be a laminate of a non-woven fabric and / or a part of the woven fabric. Moreover, as long as these are included, in order to adjust to low air permeability, the nonwoven fabric and the textile fabric may be coated with resin, for example. The air permeability of the coating material before integral foaming is preferably 100 cc / cm ² · sec or less so that the polyurethane foam raw material does not penetrate into the elastic body, and the cushioning property of the elastic body itself is not impaired. It is preferable that the material has The air permeability can be measured based on the following method.
[Air permeability]
Measured by JIS L1096 (2010) 8.26.1 A method (Fragile method). Specifically, after a test piece cut into 200 mm × 200 mm is attached to one end of a cylinder of a Frazier type tester, a suction fan and an air hole are provided so that an inclination type barometer shows a pressure of 125 Pa by an adjusting resistor. adjust. The pressure indicated by the vertical barometer at this time is measured, and the amount of air passing through the test piece is determined from the measured pressure and the air hole used of 11.8 mm using a conversion table attached to the tester. The test is performed 5 times for different test pieces, and the average value is obtained.

Polyesters such as polyethylene and polypropylene; polyurethanes; polyamides such as nylon; polyvinyl chlorides such as polyvinyl chloride and polyvinylidene chloride; polyvinyl alcohol (PVA); ethylene / vinyl acetate Polymerization (EVA) system; silicone system; and the like can be selected as appropriate, but a stretchable film, a film that shrinks by heat, and the like are preferable from the viewpoint of easy covering of the elastic body.

The type of the nonwoven fabric is not particularly limited, and can be selected from any nonwoven fabric such as a nonwoven fabric by a mechanical entanglement method such as a needle punch method or a hydroentanglement method; a thermal bond nonwoven fabric; a chemical bond nonwoven fabric; a spunbond nonwoven fabric; .
Regarding the woven fabric, the woven structure is not particularly limited, and any structure such as a plain structure, a twill structure, a satin structure, and the like can be used.

Non-woven fabrics and woven fabric materials include, for example, polyester fibers such as polyethylene terephthalate fibers, polybutylene terephthalate fibers, polylactic acid fibers and polyarylate fibers; polyolefin fibers such as polyethylene fibers and polypropylene fibers; synthetic fibers such as polyurethane fibers; Polyamide fibers such as nylon 66; polyvinyl chloride fibers such as polyvinyl chloride fibers, vinylidene fibers and polyclar fibers; polyvinyl alcohol fibers such as vinylon fibers and polyvinyl alcohol fibers; polyacrylonitrile fibers, polyacrylonitrile-vinyl chloride copolymers Suitable from acrylic fibers such as fibers; natural fibers such as cotton, hemp, hair, silk; regenerated fibers such as rayon, polynosic, cupra, and rayocell; semisynthetic fibers such as acetate fibers and triacetate fibers; It can be selected.

The basis weight of the nonwoven fabric and the woven fabric as the covering material is preferably 20 g / m ² or more, more preferably 40 g / m ² or more, preferably 100 g / m ² or less, more preferably 80 g / m ² or less. .

In the present invention, the apparent density of the container is generally 25 kg / m ³ or more, preferably 30 kg / m ³ or more, more preferably more than 45 kg / m ³ , still more preferably 50 kg / m ^3. More preferably, it is 52 kg / m ³ or more, preferably 200 kg / m ³ or less, more preferably 100 kg / m ³ or less, still more preferably 60 kg / m ³ or less. When the apparent density is lower than the lower limit, durability as a polyurethane foam is lowered, and use as a vehicle seat may be difficult. On the other hand, if the apparent density exceeds the upper limit value, the weight becomes too heavy and hard at the same time, so that the cushioning property is deteriorated, which is not preferable in practical use.
The apparent density of the elastic body is preferably 20 kg / m ³ or more, more preferably 25 kg / m ³ or more, still more preferably 28 kg / m ³ or more, and generally 200 kg / m ³ or less. Preferably, it is 100 kg / m ³ or less, more preferably 45 kg / m ³ or less, still more preferably 40 kg / m ³ or less, and particularly preferably 35 kg / m ³ or less. If the apparent density is lower than the lower limit value, sufficient cushioning and durability as a cushioning material are lost, so it is not suitable for use as a cushioning material, and if it exceeds the upper limit value, the effect of weight reduction may not be fully exhibited. This is not preferable.

In order to finish the composite cushion body lightly, a certain difference is required between the apparent density of the container and the elastic body, and the apparent density of the elastic body is preferably 0.9 times or less than the apparent density of the container. Preferably it is 0.8 times or less, More preferably, it is 0.7 times or less, Preferably it is 0.3 times or more, More preferably, it is 0.4 times or more.

The apparent density of the polyurethane foam and the elastic body means that the sample is cut into a size of 15 cm × 15 cm, left at a temperature of 20 ° C. and a humidity of 65% RH for 24 hours with no load, and the height at four locations is taken as the thickness. Then, the sample weight is measured, and the weight is divided by the sample area (= 0.0225 m ² ) × the sample volume obtained from the thickness.

The volume occupation ratio of the elastic body in the composite cushion body is preferably 5% or more, more preferably 20% or more, still more preferably 40% or more, preferably 90% or less, more preferably. It is 75% or less, more preferably 60% or less. If the volume occupancy rate of the elastic body is too low, there is a possibility that the effect of weight reduction due to the accommodation of the elastic body may not be sufficiently exerted, and if the volume occupancy rate of the elastic body becomes too high, the volume occupancy ratio of the polyurethane foam Is lower, and the seating comfort is greatly changed as compared with a cushion body made of 100% polyurethane foam.

A preferred embodiment of the composite cushion body of the present invention is shown in FIG. 1, and the II-II cut surface and the III-III cut surface in FIG. 1 are shown in FIGS. The composite cushion body 1 according to the present invention has a configuration in which the elastic body 3 is housed in a container 2 that has been prepared in advance so that the elastic body 3 can be stored.

In the present invention, a container is a container having a recess that can accommodate an elastic body. It is desirable that the container has an appropriate thickness so that the elastic body accommodated therein does not come out during use, and the thickness of the container depends on the size of the composite cushion body. However, it is preferably 10 mm or more, more preferably 15 mm or more.

As shown in FIGS. 2 to 3, it is desirable that the container 2 has a bottom part 2a which becomes the bottom of the container 2 and a side wall part 2b. Due to the presence of the bottom 2a formed of polyurethane foam, a person can directly contact the polyurethane foam, and when he / she puts his / her weight, he / she can feel a proper sinking and softness, so that the sitting comfort is improved. In addition, the presence of the side wall 2b allows the side wall to be supported even when a weight is applied, so that the cushion body can easily maintain rigidity.

It is desirable that the bottom 2a and the side wall 2b have an appropriate thickness in order to exhibit their functions.
The thickness (h1) of the bottom 2a is preferably 2 mm or more and 50 mm or less, and more preferably 5 mm or more and 40 mm or less. The thickness of the bottom portion 2a is preferably 3% or more, more preferably 10% or more, preferably 40% or less, more preferably 30% or less, with respect to the thickness (T1) of the composite cushion body. .
The thickness of the side wall 2b (for example, T _w and T _{L in} FIGS. 2 to 3) is preferably 10 mm or more, more preferably 15 mm or more, and further preferably 20 mm or more. In addition, the thickness of the side wall part 2b may be uniform in the container 2, and may differ.

It is desirable that the bottom 2a and the side wall 2b are integrally formed because there is no seam and there is little discomfort during use.

In the present invention, as long as the elastic body 3 is accommodated in the container 2, the form of the upper surface of the composite cushion body 1 does not matter. For example, as shown in FIG. 1, a lid 4 may be formed on the upper surface of the container 2 so that the elastic body 3 does not fall from the polyurethane foam.

The lid 4 may be integrated with the container 2. The state in which the lid 4 and the container 2 are integrated includes, for example, a state in which the container 2 and the lid 4 are formed by integral molding, as shown in FIG.

The material of the lid portion 4 is not particularly limited, and various examples such as plastics such as polyurethane foam, metal, and wood can be exemplified. From the viewpoint of reducing the weight of the composite cushion, plastic is preferable, and foamed plastic is preferable, and polyurethane is more preferable. It is a form. By aligning the material of the container and the lid, it is possible to reduce the feeling of foreign objects during use and to reduce the procurement cost of materials.

The thickness (h2) of the lid part 4 is preferably 2 mm or more and 20 mm or less, more preferably 5 mm or more and 15 mm or less, although it depends on the size of the composite cushion body. The thickness of the lid 4 is preferably 3% or more, more preferably 10% or more, preferably 40% or less, more preferably 20% or less with respect to the thickness (T1) of the composite cushion body. .

The size of the lid portion 4 is not particularly limited, and may be larger or smaller than the frame formed by the side wall portion 2b, but is preferably large enough to fit within the frame formed by the side wall portion 2b.

The container 2 may have an opening 5 as shown in FIG. The opening 5 is, for example, a hole through which the air in the composite cushion body 1 can flow out. When the stress is applied due to the presence of the opening 5, the air in the composite cushion body 1 is moderate. Therefore, the burden on the container 2 during use can be reduced, and the hardness of the composite cushion body 1 can be adjusted by appropriately changing the size of the opening 5.

The opening 5 may be in any position of the container 2, and may be any of the bottom surface 2 a, the side wall 2 b, and the lid 4 described above. Usually, since the composite cushion body of the present invention is used so that the bottom surface portion 2a is in contact with a person, a load is often applied to the composite cushion body 1 from the bottom surface portion 2a side. Therefore, it is preferable that the surface other than the bottom surface portion 2 a, for example, the side wall portion 2 b or the lid portion 4 has the opening 5, and more preferably the lid portion 4 so that air easily flows in and out.

The shape of the opening is not particularly limited, and may be any shape such as a polygon such as a rectangle, a circle (including an ellipse), and a stripe.

The size of the opening affects the amount of air flowing in and out through the opening. If the opening is large, the amount of air that flows out increases, so that the composite cushion body tends to be soft. However, there is a demerit that it is easy to feel the bottom. Also, if the opening is small, the amount of air flowing in and out through the opening is reduced, so that the feeling of bottoming can be reduced, but the composite cushion body tends to become hard. In order to maintain a balance between the feeling of bottoming and the hardness of the composite cushion body, the area of the opening is preferably 5 cm ² / L or more, more preferably 10 cm, per unit volume of the elastic body accommodated in the polyurethane container. ² / L or more, more preferably 12 cm ² / L or more, preferably 30 cm ² / L or less, more preferably 25 cm ² / L or less, and further preferably 22 cm ² / L or less. The area of the opening is, for example, the surface area of the elastic body that appears outside through the opening.

The number of openings is not particularly limited, and is preferably 1 or more, preferably 20 or less, more preferably 10 or less, and still more preferably 5 or less. In addition, the area of the opening in the case of providing a plurality of openings may be adjusted so that the total area of each opening satisfies the above range, and the area per opening is preferably 5 cm ² or more, more preferably It is 10 cm ² or more, preferably 100 cm ² or less, more preferably 80 cm ² or less. When the opening is rectangular, the width (W _O ) and length (L _O ) of the opening are preferably 30 mm to 120 mm (more preferably 40 mm to 100 mm).

The opening may be formed by hollowing out a part of the polyurethane foam container, but when forming the container by integral foaming, the container should be formed so that the surface of the elastic body is not exposed to the outside. Therefore, legs (protrusions) may be attached to the elastic body covered with the covering material and set in the mold so that the elastic body can be foamed in a state where it is arranged at the center of the container. Thus, when integrally foaming with the legs (projections) attached to the elastic body covered with the covering material, the resulting composite cushion body has holes derived from the legs (projections). A hole derived from this leg (protrusion) can be used as the opening.

Even when the elastic body is covered with a covering material, it is possible to provide an opening in the container. However, when the air permeability of the covering material is low, it is also assumed that air does not sufficiently flow out and in even if the opening is provided in the container. Therefore, the covering material may also have an opening. When the opening is provided in the covering material, the opening of the covering material and the opening of the container preferably overlap so that the air inside the composite cushion body can flow in and out.

<Polyurethane foam container>
The polyurethane foam used in the container may be any conventionally known polyurethane foam. Preferably, the main component is an organic isocyanate and a polyol (high molecular weight polyol, low molecular weight polyol). The resulting resin.

Examples of the organic isocyanate include 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,2′-diphenylmethane diisocyanate, 2,4′-diphenylmethane diisocyanate, 4,4′-diphenylmethane diisocyanate, 1,5-naphthalene diisocyanate, Examples include p-phenylene diisocyanate, m-phenylene diisocyanate, p-xylylene diisocyanate, m-xylylene diisocyanate, hexamethylene diisocyanate, 1,4-cyclohexane diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, isophorone diisocyanate, and the like. . These may be used alone or in combination of two or more.

As the organic isocyanate, in addition to the diisocyanate compound, a trifunctional or higher polyfunctional polyisocyanate compound can also be used. As the polyfunctional isocyanate compound, a series of diisocyanate adduct compounds such as Desmodur-N (manufactured by Bayer) and Duranate (manufactured by Asahi Kasei Kogyo) are commercially available. These trifunctional or higher functional polyisocyanate compounds are preferably used by adding to the diisocyanate compound because they are easily gelled during prepolymer synthesis when used alone.

Examples of the high molecular weight polyol include polyether polyols typified by polytetramethylene ether glycol, polyester polyols typified by polybutylene adipate, polycaprolactone polyol, and a reaction product of a polyester glycol such as polycaprolactone and alkylene carbonate. Polyester polycarbonate polyol, polyester polycarbonate polyol obtained by reacting ethylene carbonate with polyhydric alcohol and then reacting the resulting reaction mixture with organic dicarboxylic acid, and polycarbonate polyol obtained by transesterification reaction between polyhydroxyl compound and aryl carbonate Etc. These may be used alone or in combination of two or more.
In addition to the high molecular weight polyols described above as the polyol, ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, 1, Low molecular weight polyols such as 4-cyclohexanedimethanol, 3-methyl-1,5-pentanediol, diethylene glycol, triethylene glycol, and 1,4-bis (2-hydroxyethoxy) benzene may be used in combination.

More preferably, the polyurethane foam is a polyurethane foam used for a general vehicle seat. By using such a polyurethane foam, not only cushioning properties but also important performances such as durability and flame retardancy can be maintained.

<Elastic body>
An elastic body refers to an object that exhibits elasticity, for example, an object that has the property of returning to its original shape when unloaded although it deforms when stress is applied. Such an elastic body is appropriately selected from, for example, a three-dimensional reticulated cushion formed of fibers; foamed plastic such as foamed PP, foamed EVA and polyurethane foam; nonwoven fabric; hard cotton; other foamed materials; These elastic bodies may be used alone or in combination of two or more. Among them, a three-dimensional reticulated cushion body formed of fibers is preferable because it is excellent in durability, has a large amount of retained air, and can expect a damping effect utilizing the viscoelasticity of air.

The thickness (T2) of the elastic body is preferably 20 mm or more, more preferably 30 mm or more, still more preferably 35 mm or more, preferably 80 mm or less, more preferably 70 mm or less, still more preferably 55 mm or less. The thickness (T2) of the elastic body is preferably 20% or more, more preferably 40% or more, preferably 95% or less, more preferably 70% with respect to the thickness (T1) of the composite cushion body. It is as follows.
The size of the elastic body depends on the size of the container, but when the composite cushion body is used as a vehicle seat (particularly for a vehicle), the width (W2) of the elastic body is preferably 100 mm or more and 1500 mm or less. The length (L2) of the elastic body is preferably 100 mm or more and 600 mm or less.

The three-dimensional reticulated cushion body is formed by twisting a large number of continuous linear bodies each having a fiber diameter of 0.1 mm to 1.5 mm, preferably 0.2 mm to 1.0 mm made of a thermoplastic resin, in a loop shape, and The three-dimensional network is formed by fusing the contact portions with each other. For example, the thermoplastic elastic resin can be arbitrarily selected from polyester elastomers, polyamide elastomers, polyurethane elastomers, polyolefin elastomers, and the like. By using a thermoplastic elastic resin, since it can be regenerated by remelting, there is an effect that recycling becomes easy.

Examples of the polyester elastomer used in the present invention include a polyester ether block copolymer having a thermoplastic segment as a hard segment and a polyalkylene diol as a soft segment, or a polyester ether block copolymer having an aliphatic polyester as a soft segment. It can be illustrated. More specific examples of polyester ether block copolymers include terephthalic acid, isophthalic acid, naphthalene 2,6 dicarboxylic acid, naphthalene 2,7 dicarboxylic acid,

diphenyl

4,4 ′ dicarboxylic acid and other aromatic dicarboxylic acids, 1 And at least one dicarboxylic acid selected from alicyclic dicarboxylic acids such as 1,4 cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as oxalic acid, adipic acid, sebacic acid and dimer acid, or ester-forming derivatives thereof. Aliphatic diols such as 1,4 butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol and hexamethylene glycol, and alicyclic diols such as 1,1 cyclohexanedimethanol and 1,4 cyclohexanedimethanol Or this At least one diol component selected from these ester-forming derivatives and the like, and polyalkylenes such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 300 or more and 5000 or less It is a ternary block copolymer composed of at least one of diols. Considering thermal adhesiveness, hydrolysis resistance, stretchability, heat resistance, etc., dicarboxylic acid is terephthalic acid or naphthalene 2,6 dicarboxylic acid, diol component is 1,4 butanediol, polyalkylenediol Polytetraethylene glycol ternary block copolymers or polylactone terpolymer block copolymers as polyester diols are particularly preferred. As a special example, a polysiloxane-based soft segment can be used. Moreover, the said polyester elastomer can be used individually or in mixture of 2 or more types. Furthermore, a polyester elastomer blended with a non-elastomeric component, a copolymerized one, etc. can be used in the present invention.

As the polyamide-based elastomer used in the present invention, the hard segment has nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, etc. and their copolymer nylon as a skeleton, and the soft segment has an average molecular weight of about A block copolymer composed of at least one of polyalkylene diols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer of 300 or more and 5000 or less is used alone or in combination of two or more. It may be used. Further, blended or copolymerized non-elastomeric components can be used in the present invention.

The polyurethane elastomer used in the present invention is a polyether and / or polyester having (A) a hydroxyl group at the terminal having a number average molecular weight of 1000 or more and 6000 or less in the presence or absence of a normal solvent (dimethylformamide, dimethylacetamide, etc.). And (B) a prepolymer having both ends of an isocyanate group reacted with a polyisocyanate containing an organic diisocyanate as a main component and (C) a polyurethane elastomer chain-extended with a polyamine containing a diamine as a main component can be exemplified as a representative example. . Polyesters and polyethers of (A) include polybutylene adipate copolymer polyesters having an average molecular weight of about 1000 to 6000, preferably 1300 to 5000, polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide. A polyalkylene diol such as a copolymer is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used, but an isocyanate mainly composed of

diphenylmethane

4,4 ′ diisocyanate is used. A small amount of known triisocyanate may be used. As the polyamine (C), known diamines such as ethylene diamine and 1,2 propylene diamine are mainly used, and a trace amount of triamine and tetraamine may be used in combination as required. These polyurethane elastomers may be used alone or in combination of two or more.

The polyolefin-based elastomer used in the present invention is preferably a low-density polyethylene resin, particularly preferably an ethylene / α-olefin copolymer resin composed of ethylene and an α-olefin having 3 or more carbon atoms. The ethylene / α-olefin copolymer of the present invention is preferably a copolymer described in JP-A-6-293131, and is obtained by copolymerizing ethylene and an α-olefin having 3 or more carbon atoms. It is. Examples of the α-olefin having 3 or more carbon atoms include propylene, butene-1, pentene-1, hexene-1, 4-methyl-1-pentene, heptene-1, octene-1, nonene-1, and decene. -1, undecene-1, dodecene-1, tridecene-1, tetradecene-1, pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1, nonadecene-1, eicosene-1, etc., preferably butene -1, pentene-1, hexene-1, 4-methyl-1-pentene, heptene-1, octene-1, nonene-1, decene-1, undecene-1, dodecene-1, tridecene-1, tetradecene-1 Pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1, nonadecene-1, and eicosene-1. Two or more of these can also be used, and these α-olefins are usually copolymerized in an amount of 1 to 40% by weight.
This copolymer can be obtained by copolymerizing ethylene and an α-olefin using a catalyst system having a specific metallocene compound and an organometallic compound as basic components.

In the present invention, the three-dimensional reticulated cushion body is formed by twisting a continuous linear body of 300 dtex or more and 10000 dtex or less made of a thermoplastic elastic resin to form a random loop, and the respective loops are brought into contact with each other in a molten state. A three-dimensional random loop bonded structure formed by fusing portions is preferable. If the fineness of the continuous linear body of the present invention is less than 300 dtex, the strength is lowered and the repulsive force is lowered, which is not preferable. If it exceeds 10000 dtex, the number of linear members is reduced and the compression characteristics are deteriorated, so that the use portion may be limited. The fineness of the continuous linear body of the present invention is more preferably 400 dtex or more and 10000 dtex or less, and more preferably 500 dtex or more and 5000 dtex or less, from which repulsive force can be obtained. The cross-sectional shape is not particularly limited, but when a continuous linear body having a fine fineness is used, a modified cross-section or a hollow cross-section is preferable because the repulsive force is improved.

It is preferable that the 25% hardness of the reticulated cushion body in which the three-dimensional random loop formed by the continuous body of the present invention is a contact portion and is mostly fused together is 5N or more and 700N or less. If the 25% hardness is less than 5N, the repulsive force is lost, so it is unsuitable for the cushioning material. If the 25% hardness exceeds 700N, the resilience becomes strong and the sitting comfort deteriorates, so it is unsuitable for the cushioning material. It will be something. The 25% hardness of the reticulated cushion body is more preferably 20N or more and 500N or less, and further preferably 20N or more and 400N or less.

<Performance / Application>
Since the composite cushion body of the present invention is lightweight, the apparent density of the composite cushion body is preferably 53 kg / m ³ or less, more preferably 50 kg / m ³ or less, and even more preferably 45 kg / m ³ or less. . Although a minimum is not specifically limited, Usually, 15 kg / m < ³ > or more, More preferably, it is 25 kg / m < ³ > or more. In addition, the measuring method of the apparent density of the composite cushion body is the same as the measuring method of the apparent density of the polyurethane foam or the three-dimensional network cushion body described above.

The composite cushion body of the present invention has higher hardness than a conventional cushion body made of 100% polyurethane foam, and the hardness measured according to, for example, JASO B408-89 6.2 as a hardness that can be used practically. 200N / Φ200 or more can be achieved, and depending on the application, it is possible to adjust to 400N / Φ200 or more. The upper limit is not particularly limited, but is generally 600 N / Φ200 or less and may be 500 N / Φ200 or less.

The composite cushion body of the present invention is preferably used for a vehicle seat or the like. Examples of the vehicle include vehicles such as motorcycles, automobiles, railways, etc .; ships; aircrafts; baby carriages for infants, etc. The composite cushion body of the present invention is preferably applicable to vehicles, more preferably automobiles. The composite cushion body is light in weight, and has a sitting comfort such as hardness and a bottom feeling equivalent to that of a conventional polyurethane foam. A vehicle seat generally has a back surface and a seat surface, but the composite cushion body of the present invention can be applied to either the back surface and / or the seat surface of a vehicle seat.

When the composite cushion body is used for a vehicle (especially vehicle) seat, the planar shape of the composite cushion body is not particularly limited, and examples thereof include a polygon such as a rectangle and a circle (including an ellipse). When the composite cushion body is rectangular, the composite cushion body has a width of 200 mm to 1000 mm (more preferably 300 mm to 600 mm), a length of 200 mm to 1800 mm (more preferably 300 mm to 1500 mm), and high. It is desirable that the thickness is about 30 mm to 100 mm (more preferably 50 mm to 90 mm).

This application claims the benefit of priority based on Japanese Patent Application No. 2015-185704 filed on Sep. 18, 2015. The entire contents of Japanese Patent Application No. 2015-185704 filed on September 18, 2015 are incorporated herein by reference.

EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited by the following examples, but may be appropriately modified within a range that can meet the purpose described above and below. Of course, it is possible to implement them, and they are all included in the technical scope of the present invention.

[Fiber diameter of three-dimensional reticulated cushion]
A sample is cut into a size of 20 cm × 20 cm, and a linear body is collected from 10 places. The fiber diameter was measured from a photograph in which the cross section of the linear body collected at 10 locations was magnified 30 times with a microscope to obtain the fiber diameter of the three-dimensional reticulated cushion body (average value of n = 10).

[Apparent density of polyurethane foam and three-dimensional reticulated cushion]
The sample was cut into a size of 15 cm × 15 cm, left at a temperature of 20 ° C. and a humidity of 65% RH for 24 hours, then measured at four heights as thickness, and then the sample weight was measured. The apparent density was obtained by dividing the weight by the sample area (= 0.0225 m ² ) × the sample volume obtained from the thickness.

[Weight of composite cushion body]
A sample of 400 mm × 400 mm was allowed to stand for 24 hours at a temperature of 20 ° C. and a humidity of 65% RH for 24 hours, and then the weight of the entire composite cushion was measured to obtain the weight of the composite cushion.

[Hardness of composite cushion body]
It was measured according to JASO B408-89 6.2. Specifically, a test piece made of 400 mm × 400 mm was placed on a horizontal base of Tensilon, and a pressure plate having a diameter of 200 mm attached to the Tensilon was placed on the center of the upper surface of the test piece. An initial load of 5N was applied to the test piece to measure the thickness, and this was taken as the initial thickness. After compressing the pressure plate at a speed of 50 mm / min to a distance of 75% of the initial thickness, immediately remove the load, leave it for 3-5 minutes, compress it to a distance of 50% of the initial thickness, and leave it as it is After being allowed to stand for 20 seconds, the load was measured and set to 50% hardness.

[Feeling of bottom of composite cushion body by monitor test]
The composite cushion body was placed on a table without a backrest in an environment of temperature 20 ° C. and humidity 65% RH. For the six monitors, the bottom feeling felt when dropping the buttocks of the monitor to the composite cushion body at a height of 25 cm from the top surface of the composite cushion body installed on the stand is "I feel a feeling of +1 bottom very much ~ +5 bottom The evaluation was made with a five-step questionnaire “I don't feel stickiness”, and the evaluation results of the six monitors were averaged to determine the bottom feeling of the composite cushion body.

[Polyurethane foam]
The polyurethane foam in Comparative Example 1 includes a polyol “Sunfoam (registered trademark) RC-1026” manufactured by Sanyo Chemical Industries, Ltd. and a tolylene diisocyanate “Sunfoam (registered trademark) IC-505N manufactured by Sanyo Chemical Industries, Ltd. Was poured into a mold heated to 65 ° C. (W400 mm × L400 mm × T70 mm), the mold was closed, taken out after 5 minutes, and then crushed. The apparent density of the obtained polyurethane foam was 55 kg / m ³ .
As polyurethane foams in Comparative Examples 2 to 7, polyol “Sunfoam (registered trademark) RC-1026” manufactured by Sanyo Chemical Industries, Ltd. and tolylene diisocyanate “Sunfoam (registered trademark) IC manufactured by Sanyo Chemical Industries, Ltd. -505N "was mixed, poured into a mold heated to 65 ° C. (W400 mm × L400 mm × T10 mm and W400 mm × L400 mm × T15 mm), the mold was closed, taken out after 5 minutes, and then crushed. . The apparent density of the obtained polyurethane foam was 55 kg / m ³ .

[Elastic body]
As the elastic body, materials shown in Table 1 were used. The solid reticulated cushion body shown in Table 1 is “Breath Air (registered trademark)” manufactured by Toyobo Co., Ltd. The surfaces of the elastic bodies of Examples 1 to 3 were covered with a coating material. As a covering material of Example 1, as a polyethylene film “Polywrap (registered trademark)” manufactured by Ube Industries, Ltd., as a covering material of Example 2, a non-woven fabric made of polyester having a basis weight of 65 g / m ² , as a covering material of Example 3 Used a polyester fabric having a basis weight of 65 g / m ² . Each material was cut out in the size shown in the table and used.

[Production method of composite cushion body]
In Examples 1 to 3, composite cushion bodies were produced according to FIG. In Examples 1 to 3, the elastic body 3 covered with the covering material is set with four protrusions (45 mm × 45 mm × 10 mm) on the upper mold for urethane foam during urethane foaming, and Sanyo Kasei Kogyo Co., Ltd. on the lower mold. Polyol “Sunfoam® RC-1026” manufactured by Sanyo Chemical Industries, Ltd. and tolylene diisocyanate “Sunfoam® IC-505N” manufactured by Sanyo Chemical Industries, Ltd. were mixed and heated to 65 ° C. (W400 mm × L400mm × T70mm), the mold was closed, taken out after 5 minutes, and then integrally foamed by crushing. Since the composite cushion body was manufactured by integral foaming, the resulting composite cushion body had four openings 5 derived from the protrusions.

Comparative Example 1 produced a composite cushion body according to FIG. That is, the composite cushion body of Comparative Example 1 is the polyurethane foam 2 itself in which the elastic body 3 is not fitted.

In Comparative Examples 2 to 7, a three-layer laminate in which the elastic body shown in Table 1 is overlaid on the top surface of a polyurethane foam of W400 mm × L400 mm × T25 mm according to FIG. 7, and further the polyurethane foam of W400 mm × L400 mm × T20 mm is overlaid on the top surface. A composite cushion body was prepared.

In Examples 1 to 3, compared to the case where the polyurethane foam of Comparative Example 1 was used as it was, the weight of the composite cushion body tended to be light and the hardness was high. That is, even if the weight of the composite cushion body is further reduced, it can be seen that a composite cushion body with high hardness and little bottoming can be obtained by housing the elastic body in a polyurethane foam container. . In Examples 1 to 3, the elastic body is covered with a covering material, but the hardness of the composite cushion body using a nonwoven fabric or a woven fabric as the covering material is higher. This is probably because the polyurethane foam raw material is impregnated between the fibers constituting the nonwoven fabric or woven fabric, and the impregnated layer is solidified and hardened.

On the other hand, Comparative Examples 2 to 7 in which the elastic body is not accommodated in the polyurethane foam container have lower hardness than those of the polyurethane foam alone and Examples 1 to 3. That is, it can be said that it is important to increase the hardness by accommodating the elastic body in a polyurethane foam container and controlling the air flow. In Comparative Examples 2 to 7, since the amount of air flowing in and out was large, there was a feeling of bottoming and the comfort was inferior.

DESCRIPTION OF SYMBOLS 1 Composite cushion body 2 Container, 2a Bottom part, 2b Side wall part 3 Elastic body 4 Lid part 5 Opening part

Claims

A composite cushion body for a vehicle, wherein an elastic body having an apparent density lower than that of the polyurethane foam and at least partially covered with a covering material is accommodated in a polyurethane foam container.
The composite cushion body for a vehicle according to claim 1, wherein the elastic body is a three-dimensional mesh cushion body formed of fibers, foamed plastic, nonwoven fabric, or hard cotton.
The vehicle composite cushion body according to claim 1 or 2, wherein the elastic body is a three-dimensional mesh cushion body formed of fibers.
4. The apparent density of the container is 25 kg / m 3 or more and 200 kg / m 3 or less, and the apparent density of the elastic body is 20 kg / m 3 or more and 200 kg / m 3 or less. Composite cushion body for vehicles.
The vehicle composite cushion body according to any one of claims 1 to 4, wherein the container has a bottom portion and a side wall.
The vehicle composite cushion body according to any one of claims 1 to 5, wherein a thickness of the side wall is 10 mm or more.
The elastic body is set in advance in the mold, and after the foaming raw material is injected into the mold, the mold is closed, the raw material is foamed and the inside of the mold cavity is filled, and the elastic body is embedded in the polyurethane foam. The composite cushion body for a vehicle according to any one of claims 1 to 6, which is molded as described above.
The vehicle composite cushion body according to any one of claims 1 to 7, wherein the container has an opening.
The vehicle composite cushion according to any one of claims 1 to 8, wherein at least a part of the covering material is a film, a nonwoven fabric or a woven fabric.
The vehicle composite cushion body according to any one of claims 1 to 9, wherein a volume occupation ratio of the elastic body in the composite cushion body is 5% or more.