JP3589307B2

JP3589307B2 - Seat and recipe

Info

Publication number: JP3589307B2
Application number: JP14976094A
Authority: JP
Inventors: 英夫磯田; 靖司山田
Original assignee: Toyobo Co Ltd
Current assignee: Toyobo Co Ltd
Priority date: 1994-06-30
Filing date: 1994-06-30
Publication date: 2004-11-17
Anticipated expiration: 2019-11-17
Also published as: JPH0810470A

Description

【０００１】
【産業上の利用分野】
本発明は、優れたクッション性と耐熱耐久性及び振動吸収性とを有し、リサイクルが可能な車両用座席とクッション成形体の成形時、深絞り成形を省略できる座席の製法に関する。
【０００２】
【従来の技術】
現在、車両用座席は、発泡ウレタンや捲縮繊維を接着した樹脂綿や硬綿などをクッション層に使用されている。
【０００３】
しかしながら、発泡ウレタンをクッション層とした座席は、耐久性は極めて良好だが、透湿透水性に劣り蓄熱性があるため蒸れやすく、かつ、熱可塑性では無いためリサイクルが困難となり焼却される場合、焼却炉の損傷が大きく、かつ、有毒ガス除去に経費が掛かる。このため埋め立てされることが多くなったが、地盤の安定化が困難なため埋め立て場所が限定され経費も高くなっていく問題がある。また、成形加工性は優れるが製造中に使用される薬品の公害問題などもある。蒸れの改良法として特開昭６３−７７４８２号公報等が提案されているが不充分なものである。
【０００４】
蒸れを改良した座席として、クッション層にポリエステル繊維をゴム系又はウレタン系接着剤で接着した樹脂綿、例えば接着剤にゴム系を用いたものとして特開昭６０−１１３５２号公報、特開昭６１−１４１３８８号公報、特開昭６１−１４１３９１号公報等がある。又、架橋性ウレタンを用いたものとして特開昭６１−１３７７３２号公報等がある。これらのクッション層を用いた座席は耐久性に劣り、且つ、熱可塑性でなく、単一組成でもないためリサイクルも出来ない等の問題、及び加工時の煩雑さ、特に深絞り成形が難しく仕上がりが悪くなる問題がある。また、製造中に使用される薬品の公害問題などもある。
【０００５】
リサイクルが可能で、火災時、有毒な燃焼ガス発生が少ない座席になる熱接着繊維を接着剤にしたポリエステル硬綿を用いたものが、例えば特開平５−２０８４７０号公報、特開平５−２２０２７８号公報、特開平５−２４７８１５号公報、特開平５−２６９２６４号公報、特開平５−３２９９３７号公報等が提案されているが、用いている熱接着繊維の接着成分が脆い非晶性のポリマ−を用いるため接着部分が脆く、使用中に接着部分が簡単に破壊されて形態や弾力性が低下するなどの耐久性に劣る問題がある。改良法として、交絡処理する方法が特開平４−２４５９６５号公報等で提案されているが、接着部分の脆さは解決されず弾力性の低下が大きい問題がある。また、接着部分が変形しにくくソフトなクッション性を付与しにくい問題もある。なお、これらの方法では深絞り成形が困難である。耐久性を改良する方法として、接着部分を柔らかい、且つある程度変形しても回復するポリエステルエラストマ−を用い、芯成分に非弾性ポリエステルを用いた熱接着繊維を用いたポリエステル硬綿で成形したクッション材がＷＯ−９１／１９０３２号公報、特開平５−１６３６５４号公報、特開平５−３３７２５８号公報等で提案されている。ＷＯ−９１／１９０３２号公報のポリエステル硬綿はエラストマ−に非晶性成分を含有しており、熱接着部分の形成を良くしてアメーバー状の接着部を形成しているが塑性変形しやいため、及び芯成分が非弾性ポリエステルのため、特に加熱下での塑性変形が著しくなり、耐熱抗圧縮性が低下する問題点がある。これらの改良法として、特開平５−１６３６５４号公報にシ−ス成分にイソフタル酸を含有するポリエステルエラストマ−、コア成分に非弾性ポリエステルを用いた熱接着複合繊維のみからなる構造体が提案されているが上述の理由で加熱下での塑性変形が著しくなり、耐熱抗圧縮性が低下するので車両用座席のクッション材に使用するには問題がある。他方、特開平５−３３７２５８号公報では、エラストマ−に非晶性成分を含有しないため、耐熱耐久性は改善され、アニ−リングで更に耐熱耐久性を向上させているが、非エラストマ−成分を含有するので、発泡ポリウレタンに比較して未だ耐久性は不充分である。また、繊維を熱成形するので、成形時の煩雑さが解決されていない問題がある
【０００６】
土木工事用に使用する熱可塑性のオレフィン網状体が特開昭４７−４４８３９号公報に開示されている。が、素材がオレフィンのため耐熱耐久性が著しく劣り車両用座席のクッション材には使用ができないものである。また、特開平１−２０７４６２号公報では、塩化ビニ−ル製のフロアマットの開示があるが、室温での圧縮回復性が悪く、耐熱性は著しく悪いので、車両用座席のクッション材としては好ましくないものである。なお、網状構造体は難燃性や振動減衰、及び、成形加工に関する配慮が全くなされていない。
【０００７】
【発明が解決しようとする課題】
上記問題点を解決し、振動を遮断し、耐熱耐久性、形態保持性、クッション性の優れた蒸れ難い、燃焼ガスの毒性指数が低く安全性の高い熱可塑性弾性樹脂網状体をクッション材に用いた車両用座席と深絞り成形を簡略化した製法を提供することを目的とする。
【０００８】
【課題を解決するための手段】
上記課題を解決するための手段、即ち本発明は、主要部として、側地、クッション層、裏面深絞り形状部より形成された背部と座部よりなる座席であり、座席裏面深絞り形状部が開孔率１０％以上の射出成形された樹脂成形体からなり、クッション層が繊度が１０００００デニ−ル以下の連続した線条を曲がりくねらせ互いに接触させて該接触部の大部分が融着した３次元立体構造体を形成した熱可塑性弾性樹脂からなる見掛け密度が０．０１ｇ／ｃｍ^３から０．２ｇ／ｃｍ^３の網状体で構成され、該樹脂成形体と該網状体が一体接合されていることを特徴とする座席、雌型に所定形状に切断されたクッション層となる網状体を配し、その上に裏面又は背面となる深絞り形状に成形された樹脂成形体を配し、又は網状体と樹脂成形体間に網状体の融点より少なくとも１０℃以上低い融点を持つ接着層を配して、雄型で上からクッション層を圧縮すると共に樹脂成形体を介して凹部内側からも凸部を圧縮し、網状体の融点より５℃高い温度〜融点より５０℃低い温度の加熱媒体で加熱して熱成形により一体化した後、一旦冷却するか、又は連続して、網状体のガラス転移温度より１０℃高い温度以上、融点より２０℃以上低い温度でアニ−リングして得たクッション成形体に側地を取付けて、座席フレ−ムに固定することを特徴とする座席の製法である。
【０００９】
本発明における熱可塑性弾性樹脂とは、ソフトセグメントとして分子量３００〜５０００のポリエ−テル系グリコ−ル、ポリエステル系グリコ−ル、ポリカ−ボネ−ト系グリコ−ルまたは長鎖の炭化水素末端をカルボン酸または水酸基にしたオレフィン系化合物等をブロック共重合したポリエステル系エラストマ−、ポリアミド系エラストマ−、ポリウレタン系エラストマ−、ポリオレフィン系エラストマ−などが挙げられる。熱可塑性弾性樹脂とすることで、再溶融により再生が可能となるため、リサイクルが容易となる。例えば、ポリエステル系エラストマ−としては、熱可塑性ポリエステルをハ−ドセグメントとし、ポリアルキレンジオ−ルをソフトセグメントとするポリエステルエ−テルブロック共重合体、または、脂肪族ポリエステルをソフトセグメントとするポリエステルエステルブロック共重合体が例示できる。ポリエステルエ−テルブロック共重合体のより具体的な事例としては、テレフタル酸、イソフタル酸、ナフタレン２・６ジカルボン酸、ナフタレン２・７ジカルボン酸、ジフェニル４・４’ジカルボン酸等の芳香族ジカルボン酸、１・４シクロヘキサンジカルボン酸等の脂環族ジカルボン酸、琥珀酸、アジピン酸、セバチン酸ダイマ−酸等の脂肪族ジカルボン酸または、これらのエステル形成性誘導体などから選ばれたジカルボン酸の少なくとも１種と、１・４ブタンジオ−ル、エチレングリコ−ル、トリメチレングリコ−ル、テトレメチレングリコ−ル、ペンタメチレングリコ−ル、ヘキサメチレングリコ−ル等の脂肪族ジオ−ル、１・１シクロヘキサンジメタノ−ル、１・４シクロヘキサンジメタノ−ル等の脂環族ジオ−ル、またはこれらのエステル形成性誘導体などから選ばれたジオ−ル成分の少なくとも１種、および平均分子量が約３００〜５０００のポリエチレングリコ−ル、ポリプロピレングリコ−ル、ポリテトラメチレングリコ−ル、エチレンオキシド−プロピレンオキシド共重合体等のポリアルキレンジオ−ルのうち少なくとも１種から構成される三元ブロック共重合体である。ポリエステルエステルブロック共重合体としては、上記ジカルボン酸とジオ−ル及び平均分子量が約３００〜５０００のポリラクトン等のポリエステルジオ−ルのうち少なくとも各１種から構成される三元ブロック共重合体である。熱接着性、耐加水分解性、伸縮性、耐熱性等を考慮すると、ジカルボン酸としてはテレフタル酸、または、及びナフタレン２・６ジカルボン酸、ジオ−ル成分としては１・４ブタンジオ−ル、ポリアルキレンジオ−ルとしてはポリテトラメチレングリコ−ルの３元ブロック共重合体または、ポリエステルジオ−ルとしてポリラクトンの３元ブロック共重合体が特に好ましい。特殊な例では、ポリシロキサン系のソフトセグメントを導入したものも使うこたができる。また、上記エラストマ−に非エラストマ−成分をブレンドされたもの、共重合したもの、ポリオレフィン系成分をソフトセグメントにしたもの等も本発明の熱可塑性弾性樹脂に包含される。ポリアミド系エラストマ−としては、ハ−ドセグメントにナイロン６、ナイロン６６、ナイロン６１０、ナイロン６１２、ナイロン１１、ナイロン１２等及びそれらの共重合ナイロンを骨格とし、ソフトセグメントには、平均分子量が約３００〜５０００のポリエチレングリコ−ル、ポリプロピレングリコ−ル、ポリテトラメチレングリコ−ル、エチレンオキシド−プロピレンオキシド共重合体等のポリアルキレンジオ−ルのうち少なくとも１種から構成されるブロック共重合体を単独または２種類以上混合して用いてもよい。更には、非エラストマ−成分をブレンドされたもの、共重合したもの等も本発明に使用できる。ポリウレタン系エラストマ−としては、通常の溶媒（ジメチルホルムアミド、ジメチルアセトアミド等）の存在または不存在下に、（Ａ）数平均分子量１０００〜６０００の末端に水酸基を有するポリエ−テル及び又はポリエステルと（Ｂ）有機ジイソシアネ−トを主成分とするポリイソシアネ−トを反応させた両末端がイソシアネ−ト基であるプレポリマ−に、（Ｃ）ジアミンを主成分とするポリアミンにより鎖延長したポリウレタンエラストマ−を代表例として例示できる。（Ａ）のポリエステル、ポリエ−テル類としては、平均分子量が約１０００〜６０００、好ましくは１３００〜５０００のポリブチレンアジペ−ト共重合ポリエステルやポリエチレングリコ−ル、ポリプロピレングリコ−ル、ポリテトラメチレングリコ−ル、エチレンオキシド−プロピレンオキシド共重合体からなるグリコ−ル等のポリアルキレンジオ−ルが好ましく、（Ｂ）のポリイソシアネ−トとしては、従来公知のポリイソシアネ−トを用いることができるが、ジフェニルメタン４・４’ジイソシアネ−トを主体としたイソシアネ−トを用い、必要に応じ従来公知のトリイソシアネ−ト等を微量添加使用してもよい。（Ｃ）のポリアミンとしては、エチレンジアミン、１・２プロピレンジアミン等公知のジアミンを主体とし、必要に応じて微量のトリアミン、テトラアミンを併用してもよい。これらのポリウレタン系エラストマ−は単独又は２種類以上混合して用いてもよい。なお、本発明の熱可塑性弾性樹脂の融点は耐熱耐久性が保持できる１４０℃以上が好ましく、１６０℃以上のものを用いると耐熱耐久性が向上するのでより好ましい。なお、本発明の網状体は難燃性を付与するため燐系化合物を含有させるため、熱安定性が難燃剤を含有しないものよりやや劣るので必要に応じ、抗酸化剤等を添加して耐熱性や耐久性を向上させるのが特に好ましい。抗酸化剤は、好ましくはヒンダ−ド系抗酸化剤としては、ヒンダ−ドフェノ−ル系とヒンダ−ドアミン系があり、窒素を含有しないヒンダ−ドフェノ−ル系抗酸化剤を１％〜５％添加して熱分解を抑制すると燃焼時の致死量が少ない有毒ガスの発生を抑えられるので特に好ましい。本発明の目的である振動や応力の吸収機能をもたせる成分を構成する熱可塑性弾性樹脂のソフトセグメント含有量は好ましくは１５重量％以上、より好ましくは３０重量％以上であり、耐熱耐へたり性からは８０重量％以下が好ましく、より好ましくは７０重量％以下である。即ち、本発明の弾性網状体の振動や応力の吸収機能をもたせる成分のソフトセグメント含有量は好ましくは１５重量％以上８０重量％以下であり、より好ましくは３０重量％以上７０重量％以下である。
【００１０】
本発明の座席に用いる網状体及び他の部位に用いる熱可塑性弾性樹脂は難燃性を有するのが好ましく、特に燐含有組成物がハロゲン系組成物よりより好ましい。難燃性を有する網状体は熱可塑性弾性樹脂中に燐含有量（Ｂｐｐｍ）がソフトセグメント含有量（Ａ重量％）に対し、６０Ａ＋２００以上を満足しない場合は難燃性が劣り、１０００００ｐｐｍを越えると可塑化効果による塑性変形が大きくなり熱可塑性弾性樹脂の耐熱性が劣るので、６０Ａ＋２００≦Ｂ≦１０００００の関係を満足するのが好ましい。より好ましい燐含有量（Ｂｐｐｍ）はソフトセグメント含有量（Ａ重量％）に対し、３０Ａ＋１８００≦Ｂ≦１０００００であり、更に好ましい燐含有量（Ｂｐｐｍ）はソフトセグメント含有量（Ａ重量％）に対し、１６Ａ＋２６００≦Ｂ≦５００００である。難燃性は多量のハロゲン化物と無機物を添加して高度の難燃性を付与する方法があるが、燃焼時に致死量の少ない有毒なハロゲンガスを多量に発生し、火災時の中毒の問題があり、焼却時には、焼却炉の損傷が大きくなる問題がある。本発明では、ハロゲン化物の含有量は少なくとも１重量％以下が好ましく、より好ましくは、ハロゲン化物の含有量は０．５重量％以下、最も好ましくはハロゲン化物を含有しないものである。本発明の好ましい燐系難燃剤としては、例えば、ポリエステル系熱可塑性弾性樹脂の場合、樹脂重合時に、ハ−ドセグメント部分に難燃剤として、例えば特開昭５１−８２３９２号公報等に記載された１０〔２・３・ジ（２・ヒドロキシエトキシ）−カルボニルプロピル〕９・１０・ジヒドロ・９・オキサ・１０ホスファフェナレンス・１０オキシロ等のカルボン酸をハ−ドセグメントの酸成分の一部として共重合したポリエステル系熱可塑性弾性樹脂とする方法や、熱可塑性弾性樹脂に後工程で、例えば、トリス（２・４−ジ−ｔ−ブチルフェニル）フスファイト等の燐系化合物を添加して難燃性を付与することができる。その他、難燃性を付与できる難燃剤としては、各種燐酸エステル、亜燐酸エステル、ホスホン酸エステル（必要に応じハロゲン元素を含有する上記燐酸エステル類）、もしくはこれら燐化合物から誘導される重合物が例示できる。本発明は、熱可塑性弾性樹脂中に各種改質剤、添加剤、着色剤等を必要に応じて添加できる。本発明の網状体は、好ましくは難燃性を付与するために燐を含有させており、この理由は、上記している如く、安全性の観点から、火災時に発生するシアンガス、ハロゲンガス等の致死量の少ない有毒ガスをできるだけ少なくすることにある。このため、本発明での好ましい難燃性網状体の燃焼ガスの毒性指数は好ましくは６以下、より好ましくは５．５以下である。また、側地やワディング層にポリエステル繊維を使用される場合、好ましくはポリエステル系熱可塑性弾性樹脂とすることで分別せずに再生リサイクルができる。
【００１１】
本発明の座席は、主要部として側地、クッション層、裏面深絞り形状部より形成された背部と座部よりなる座席である。
本発明での網状体を構成する熱可塑性弾性樹脂からなる線条は、示差走査型熱量計にて測定した融解曲線において、融点以下に吸熱ピ−クを有するのが好ましい。融点以下に吸熱ピ−クを有するものは、耐熱耐へたり性が吸熱ピ−クを有しないものより著しく向上する。例えば、本発明の好ましいポリエステル系熱可塑性樹脂として、ハ−ドセグメントの酸成分に剛直性のあるテレフタル酸やナフタレン２・６ジカルボン酸などを９０モル％以上含有するもの、より好ましくはテレフタル酸やナフタレン２・６ジカルボン酸の含有量は９５モル％以上、特に好ましくは１００モル％とグリコ−ル成分をエステル交換後、必要な重合度まで重合し、次いで、ポリアルキレンジオ−ルとして、好ましくは平均分子量が５００以上５０００以下、特に好ましくは１０００以上３０００以下のポリテトラメチレングリコ−ルを１５重量％以上７０重量％以下、より好ましくは３０重量％以上６０重量％以下共重合量させた場合、ハ−ドセグメントの酸成分に剛直性のあるテレフタル酸やナフタレン２・６ジカルボン酸の含有量が多いとハ−ドセグメントの結晶性が向上し、塑性変形しにくく、かつ、耐熱抗へたり性が向上するが、溶融熱接着後更に融点より少なくとも１０℃以上低い温度でアニ−リング処理するとより耐熱抗へたり性が向上する。圧縮歪みを付与してからアニ−リングすると更に耐熱抗へたり性が向上する。このような処理をした網状構造体の線条を示差走査型熱量計で測定した融解曲線に室温以上融点以下の温度で吸熱ピークをより明確に発現する。なおアニ−リングしない場合は融解曲線に室温以上融点以下に吸熱ピ−クを発現しない。このことから類推するに、アニ−リングにより、ハ−ドセグメントが再配列され、疑似結晶化様の架橋点が形成され、耐熱抗へたり性が向上しているのではないかとも考えられる。（この処理を疑似結晶化処理と定義する）この疑似結晶化処理効果は、ポリアミド系弾性樹脂やポリウレタン系弾性樹脂にも有効である。
【００１２】
本発明座席に使用する側地や樹脂成形体を構成する熱可塑性非弾性樹脂とは、ポリエステル、ポリアミド、ポリオレフィン等が例示できる。なお、本発明ではガラス転移点温度が少なくとも４０℃以上のものを使用するのが好ましい。例えば、ポリエステルでは、ポリエチレンテレフタレ−ト（ＰＥＴ）、ポリエチレンナフタレ−ト（ＰＥＮ）、ポリシクロヘキシレンジメチレンテレフタレ−ト（ＰＣＨＤＴ）、ポリシクロヘキシレンジメチレンナフタレ−ト（ＰＣＨＤＮ）、ポリブチレンテレフタレ−ト（ＰＢＴ）、ポリブチレンナフタレ−ト（ＰＢＮ）、ポリアリレ−ト等、及びそれらの共重合ポリエステル等が例示できる。ポリアミドでは、ポリカプロラクタム（ＮＹ６）、ポリヘキサメチレンアジパミド（ＮＹ６６）、ポリヘキサメチレンセバカミド（ＮＹ６−１０）等が例示できる。ポリオレフィンとしては、ポリプロピレン（ＰＰ）、ポリブテン・１（ＰＢ・１）等が例示できる。本発明に用いる熱可塑性非弾性樹脂としては、クッション材の側地にポリエステルを用いる場合が多いので、廃棄する場合に分離せずにリサイクルが可能なクッション素材として、耐熱性も良好なＰＥＴ、ＰＥＮ、ＰＢＮ、ＰＣＨＤＴ等のポリエステルが特に好ましい。なお、樹脂成形体に用いる場合は、必要強度を保持した範囲で耐衝撃性を向上させる成分、例えば熱可塑性弾性樹脂やガラス転移点温度の低いＰＢＴ，ポリプロピレンテレフタレ−ト（ＰＰＴ）、ポリヘキシレンテレフタレ−ト等を５％未満添加するのが好ましい。本発明の好ましい実施形態である難燃性を有する網状体は熱可塑性非弾性樹脂中に燐含有量は、１０００ｐｐｍ未満では、難燃性が不充分であり、２０００００ｐｐｍを越えると可塑化効果による塑性変形が大きくなり熱可塑性非弾性樹脂の耐熱性が劣るので、１０００ｐｐｍ以上２００００ｐｐｍ以下含有するのが良い。より好ましい燐含有量は２０００ｐｐｍ以上１００００ｐｐｍ以下、最も好ましくは３０００ｐｐｍ以上８０００ｐｐｍである。難燃性は多量のハロゲン化物と無機物を添加して高度の難燃性を付与する方法があるが、燃焼時に致死量の少ない有毒なハロゲンガスを多量に発生し、火災時の中毒の問題があり、焼却時には、焼却炉の損傷が大きくなるので好ましくは含有しないものが良い。特に塩化ビニ−ルは自己消火性を有するが燃焼すると有毒ガスを多く発生するので本発明に用いるのは好ましくない。本発明では、ハロゲン化物の含有量は少なくとも１重量％以下、好ましくは、ハロゲン化物の含有量は０．５重量％以下、より好ましくはハロゲン化物を含有しないものである。本発明の燐系難燃剤としては、例えば、ポリエステル系熱可塑性非弾性樹脂の場合、樹脂重合時に、難燃剤として、例えば特開昭５１−８２３９２号公報等に記載された１０〔２・３・ジ（２・ヒドロキシエトキシ）−カルボニルプロピル〕９・１０・ジヒドロ・９・オキサ・１０ホスファフェナレンス・１０オキシロ等のカルボン酸を酸成分の一部として共重合したポリエステル系熱可塑性非弾性樹脂とする方法や、熱可塑性非弾性樹脂を射出成形時の後工程で、例えば、トリス（２・４−ジ−ｔ−ブチルフェニル）フスファイト等の燐系化合物を添加して難燃性を付与することができる。その他、難燃性を付与できる難燃剤としては、各種燐酸エステル、亜燐酸エステル、ホスホン酸エステル（必要に応じハロゲン元素を含有する上記燐酸エステル類）、もしくはこれら燐化合物から誘導される重合物が例示できる。本発明は、熱可塑性非弾性樹脂中に各種改質剤、添加剤、着色剤等を必要に応じて添加できる。本発明の座席を構成するクッション体は、難燃性を付与するために燐を含有させており、この理由は、上記している如く、安全性の観点から、火災時に発生するシアンガス、ハロゲンガス等の致死量の少ない有毒ガスをできるだけ少なくすることにある。このため、本発明の座席を構成するクッション体の燃焼ガスの毒性指数は好ましくは６以下、より好ましくは５．５以下である。また、側地やワディング層に好ましくはポリエステル系熱可塑性非弾性樹脂とすることで分別せずに再生リサイクルができる。
【００１３】
本発明は、座席裏面又は背面の深絞り形状部が開孔率１０％以上の射出成形された樹脂成形体からなり、クッション層が繊度が１０００００デニ−ル以下の連続した線条を曲がりくねらせ互いに接触させて該接触部の大部分が融着した３次元立体構造体を形成した熱可塑性弾性樹脂からなる見掛け密度が０．０１ｇ／ｃｍ^３から０．２ｇ／ｃｍ^３の網状体で構成され、該樹脂成形体と該網状体が接着剤または自己接着により一体接合され、表面に側地を配した座席（第１図に座席の断面図、第２図（Ａ）に座部のＡ−Ａ’間の断面、第２図（Ｂ）に背部のＢ−Ｂ’間の断面を発明の一例として示す。）である。本発明の座席は、座席裏面又は背面の深絞り形状部を開孔率が１０％以上の樹脂成形体（第３図に座部用の樹脂成形体、第４図に背部用の樹脂成形体を発明の一例として示す。）とする事で、熱可塑性弾性樹脂からなる弾力性と回復性の優れた網状体からなるクッション層から受ける局部的な応力を接合一体化した樹脂成形体が面全体で受ける補強機能を有すると共に、サイド部などの凸の芯材の働きも兼ね備えるために必要である。網状体と樹脂成形体が接合一体化していない場合は局部的に大きい変形を受けると網状体構造が破壊される場合があるので好ましくない。樹脂成形体の形状は、耐圧構造化、例えば補強梁構造を有するものや、中空構造化したものが好ましい。このことで金属からなるフレ−ム部材を少なく出来、軽量化ができる。座席裏面又は背面の深絞り形状部もクッション層としたものは不織布の補強層および、金属製補強フレ−ムが必要なため座席重量が重くなるので好ましくない。しかして、樹脂成形体には、後述する成形加工時に加熱流体を貫通させる必要と、座席使用時の通気性保持のため開孔率が１０％以上必要である。１０％未満では、成形時の昇温速度が遅くなり、局部的に熱劣化したり、形状形成が不良になったりして好ましくない。また、網状体の通気性が良好でも背面の通気が不充分になると蒸れやすくなるので好ましくない。蒸れ防止の目的からはサイド部は開孔部が無くてもよいが、好ましくは全面に開孔部があるのが望ましい。本発明の樹脂成形体の開孔率は、好ましくは２０％から７０％、より好ましくは３０％から５０％である。本発明のクッション層は繊度が１０００００デニ−ル以下の連続した線条を曲がりくねらせ互いに接触させて該接触部の大部分が融着した３次元立体構造体を形成した熱可塑性弾性樹脂からなる見掛け密度が０．０１ｇ／ｃｍ^３から０．２ｇ／ｃｍ^３の網状体で構成されているので、外部から与えられた振動を熱可塑性弾性樹脂の振動吸収機能で大部分の振動を吸収減衰し、局部的に大きい変形応力を与えられた場合でも網状体の表面が熱成形により実質的にフラット化され接触部の大部分が融着しており、クッション層の面で変形応力を受け止め変形応力を分散させ、熱可塑性弾性樹脂からなる線条が３次元立体構造体を形成し融着一体化されて補強機能を持つ樹脂成形体と一体化しているので、座席構造を保持して、網状体は容易に構造体全体が変形してエネルギ−変換により変形応力を吸収し、変形応力が解除されると熱可塑性弾性樹脂のゴム弾性で容易に元の形態に回復する機能があるので耐へたり性が良好である。公知の非弾性樹脂のみからなる線条で構成した網状体では、ゴム弾性を持たないので圧縮変形により塑性変形を生じて回復しなくなり耐久性が劣る。なお、網状体の線条が連続していない場合は、接着点が応力の伝達点となるため接着点に著しい応力集中が起こり構造破壊を生じ前記従来技術にも例示した特開昭６０−１１３５２号公報、特開昭６１−１３７７３２号公報、ＷＯ９１−１９０３２号公報等に開示された構造体の如く耐熱耐久性が劣り好ましくない。また、非弾性樹脂よりなる繊維をマトリックスとした硬綿では、塑性変形を生じて耐へたり性が劣るのでクッション層に用いるには好ましくない。融着していない場合は、形態保持が出来ず、構造体が一体で変形しないため、応力集中による疲労現象が起こり耐久性が劣ると同時に、形態が変形して体型保持ができなくなるので好ましくない。本発明のより好ましい融着の程度は、線条が接触している部分の大半が融着した状態であり、もっとも好ましくは接触部分が全て融着した状態である。なお、クッション材の機能は、基本のクッション層は繊度を少し太くして少し硬くして体型保持を受け持つ層と振動減衰性の良い成分で密度を少し高くした振動吸収して振動を遮断する層で構成し、表面層はやや繊度を細くし構成線条本数を多くした少し柔らかな層として適度の沈み込みにより快適な臀部のタッチを与えて臀部の圧力分布を均一分散化させると共にクッション層で吸収できなかった振動を吸収して人体の共振部分の振動を遮断する層が一体化されることで、応力や振動を一体で変形し吸収させ座り心地を向上させることができる。かくして、振動吸収性と弾性回復性の良い熱可塑性弾性樹脂からなる連続した線条が接触部の大部分が融着した３次元立体構造体を形成し融着一体化され表面が実質的にフラット化されたクッション層とクッション層の裏面に補強機能を持つ樹脂成形体が接着剤または自己接着により一体接合したクッション体は、表面層は面で変形応力を受け止め応力の分散を良くし、個々の線状に掛かる応力を少なくして樹脂成形体で支えられ、網状構造全体が形態保持しつつ変形して変形応力を吸収し、且つ臀部を支えるクッション性も向上させ、応力が解除されると回復し、フレ−ムから伝わる振動も振動吸収性と弾性回復性の良い熱可塑性弾性樹脂からなるクッション層が吸収して人体の共振部分の振動を遮断して座り心地と耐久性を向上させることができる。本発明の網状体を形成する振動吸収性と弾性回復性の良い熱可塑性弾性樹脂からなる線条の繊度は１０００００デニ−ル以下である。座席のクッション層の見掛け密度を０．２ｇ／ｃｍ^３以下にした場合、１０００００デニ−ルを越えると構成本数が少なくなり、密度斑を生じて部分的に耐久性の悪い構造ができ、応力集中による疲労が大きくなり耐久性が低下するので好ましくない。本発明の熱可塑性弾性樹脂からなる線条の繊度は、繊度が細すぎると抗圧縮性が低くなり過ぎて変形による応力吸収性が低下するので１００デニ−ル以上であり、構成本数の低下による構造面の緻密性を損なわない５００００デニ−ル以下である。より好ましくは５００デニ−ル以上、１００００デニ−ル以下である。本発明のクッション層を形成する網状体の平均の見掛け密度は、０．００５ｇ／ｃｍ^３では反発力が失われ、振動吸収能力や変形応力吸収能力が不充分となりクッション機能を発現させにくくなる場合があり、０．２５ｇ／ｃｍ^３以上では反発力が高すぎて座り心地が悪くなる場合があるので、振動吸収能力や変形応力吸収機能が生かせてクッション体としての機能が発現されやすい０．０１ｇ／ｃｍ^３以上０．２０ｇ／ｃｍ^３以下であり、好ましくは０．０３ｇ／ｃｍ^３以上０．０８ｇ／ｃｍ^３以下である。本発明においては繊度の異なる線状を見掛け密度との組合せで最適な構成とする異繊度積層構造とする方法も好ましい実施形態として選択できる。本発明の網状体の厚みは特に限定されないが、厚みが５ｍｍ未満では応力吸収機能と応力分散機能が低下するので、好ましい厚みは力の分散をする面機能と振動や変形応力吸収機能が発現できる厚みとして１０ｍｍ以上であり、より好ましくは２０ｍｍ以上である。なお、本発明座席の樹脂成形体と網状体を接合一体化する方法に、接着剤を用いる場合は、接着剤としては、網状体と樹脂成形体の両方に良好な接着性を有する樹脂が好ましく、特には熱接着性を有するものが良い。特に好ましい実施形態としては、例えば、網状体がポリエステル系熱可塑性弾性樹脂で、樹脂成形体がポリエステル系熱可塑性弾性樹脂又は、ポリエステル系熱可塑性非弾性樹脂の場合、少なくとも網状体の熱可塑性弾性樹脂の融点より１０℃以上低い融点のポリエステル系樹脂が良い。好ましくは、網状体の融点より２０℃から５０℃低い融点のものが良い。クッション層の変形に耐えるためには、熱可塑性弾性樹脂が特に好ましい。接着剤の形態は特には限定されないが、フィルム、不織布、粉末又は溶液状のものを塗布する等の方法があるが、取り扱い上からと熱風を貫通させて熱接着させるので不織布が特に好ましい。不織布としては、熱可塑性弾性樹脂からなるスパンボンド不織布、メルトブロ−不織布、又は、短繊維不織布などが使える。自己接着の場合は、網状体の線条に熱接着機能を付与するため、高融点成分と低融点成分のシ−ス・コア構造又はサイドバイサイド構造とした線条で網状体を形成する。網状体の線条を複合構造とした場合、好ましい熱接着機能も付与できる。例えば、シ−スコア構造ではシ−ス成分の振動や変形応力をエネルギ−変換が容易なソフトセグメント含有量が多い熱可塑性弾性樹脂を熱接着成分とし、コア成分の抗圧縮性を示すソフトセグメント含有量が少ない熱可塑性弾性樹脂を網状形態の保持機能をもたせるための高融点成分とする構成で、熱接着成分の融点を高融点樹脂の融点より１０℃以上低くしたものを用いることにより熱接着機能も付与できる。また、本発明の難燃性補強網状体の表面層を振動や変形応力をエネルギ−変換が容易なソフトセグメント含有量が多い低融点の熱可塑性弾性樹脂を熱接着成分とし積層することでも好ましい熱接着機能を付与できる。熱接着機能を発現させるに好ましい網状体中の線条を形成する熱接着成分の融点は高融点成分の融点より１５℃から５０℃低い融点であり、より好ましくは２０℃から４０℃低い融点である。かかるクッション機能を持つクッション体に側地を被せてフレ−ムに固定された、例えば第１図の断面を有する本発明の座席は振動を遮断し、耐熱耐久性、形態保持性、クッション性の優れた蒸れにくい車両用座席である。なお、本発明座席の側地は安全性の観点からは難燃性のものを用いるのが特に好ましい。
【００１４】
本発明座席の網状体と側地の間にファイバ−フィルからなるワディング層を配することで、座席のタッチを柔らかくする効果があるので好ましい。ワヂィング層は、熱接着繊維が熱可塑性弾性樹脂からなる繊維を用いた場合、耐熱耐久性とクッション性が良好となるので特に好ましい。熱接着繊維に熱可塑性非弾性樹脂からなる繊維を用いた場合、耐熱耐久性が劣るので好ましくない。ワヂィング層を側地とクッション層との熱接着成分として使用する場合は網状体の熱可塑性弾性樹脂の融点より少なくとも１０℃以上低い融点の熱可塑性弾性樹脂を熱接着成分とした繊維を用いることで網状構造を保持して網状体および側地との熱接着が可能となるので好ましい実施形態である。
【００１５】
本発明では網状体の線条の断面形状は特には限定されないが、中空断面や異形断面にすることで好ましい抗圧縮性（反発力）やタッチを付与することができるので特に好ましい。抗圧縮性は繊度や用いる素材のモジュラスにより調整して、繊度を細くしたり、柔らかい素材では中空率や異形度を高くし初期圧縮応力の勾配を調整できるし、繊度をやや太くしたり、ややモジュラスの高い素材では中空率や異形度を低くして座り心地が良好な抗圧縮性を付与する。中空断面や異形断面の他の効果として中空率や異形度を高くすることで、同一の抗圧縮性を付与した場合、より軽量化が可能となり、自動車等の座席に用いると省エネルギ−化ができる。好ましい抗圧縮性（反発力）やタッチを付与することができる他の好ましい方法として、本発明の網状体の線条を複合構造とする方法がある。複合構造としては、シ−スコア構造またはサイドバイサイド構造及びそれらの組合せ構造などが挙げられる。が、特にはクッション層が大変形してもエネルギ−変換できない振動や変形応力をエネルギ−変換して回復できる立体３次元構造とするために線状の表面の５０％以上を柔らかい熱可塑性弾性樹脂が占めるシ−スコア構造またはサイドバイサイド構造及びそれらの組合せ構造などが挙げられる。すなわち、シ−スコア構造ではシ−ス成分は振動や変形応力をエネルギ−変換が容易なソフトセグメント含有量が多い熱可塑性弾性樹脂とし、コア成分は抗圧縮性を示すソフトセグメント含有量が少ない熱可塑性弾性樹脂で構成し適度の沈み込みによる臀部への快適なタッチを与えることができる。サイドバイサイド構造では振動や変形応力をエネルギ−変換が容易なソフトセグメント含有量が多い熱可塑性弾性樹脂の溶融粘度をソフトセグメント含有量が少ない抗圧縮性を示す熱可塑性弾性樹脂の溶融粘度より低くして線状の表面を占めるソフトセグメント含有量が多い熱可塑性弾性樹脂の割合を多くした構造（比喩的には偏芯シ−ス・コア構造のシ−スに熱可塑性弾性樹脂を配した様な構造）として線状の表面を占めるソフトセグメント含有量が多い熱可塑性弾性樹脂の割合を８０％以上としたものが特に好ましく、最も好ましくは線状の表面を占めるソフトセグメント含有量が多い熱可塑性弾性樹脂の割合を１００％としたシ−スコアである。ソフトセグメント含有量が多い熱可塑性弾性樹脂の線状の表面を占める割合が多くなると、溶融して融着するときの流動性が高いので接着が強固になる効果があり、構造が一体で変形する場合、接着点の応力集中に対する耐疲労性が向上し、耐熱性や耐久性がより向上する。
【００１６】
次に本発明の製法を述べる。本発明での網状体は、本発明がなされた時点では公知ではないので特に詳細にその製法を述べる。複数のオリフィスを持つ多列ノズルより熱可塑性弾性樹脂を各ノズルオリフィスに分配し、該熱可塑性樹脂の融点より２０℃以上、８０℃未満高い溶融温度で、該ノズルより下方に向けて吐出させ、溶融状態で互いに接触させて融着させ３次元構造を形成しつつ、引取り装置で挟み込み冷却槽で冷却せしめて連続した網状体を得る。本発明では、前記の如く、難燃性を必要条件とはしないが必要に応じ難燃性を付与するために、燐化合物を重合時に添加して共重合する方法と重合後に添加して混合練り込みする方法ができる。混合練り込みは二軸混練押出機又はダルメ−ジ、ピン等の混練機能をもつ単軸押出機を用い、溶融押し出し前に行う場合と、溶融押し出し時に定量供給等の方法で行う場合を選択できる。難燃剤の定量供給が出来れば溶融押し出し時に混練するのが最も安価な方法となる。このような方法で好ましくはソフトセグメント量（Ａ重量％）と燐含有量（Ｂｐｐｍ）が６０Ａ＋２００≦Ｂ≦１０００００の関係を満足する燐含有量を熱可塑弾性樹脂に添加して、次いで溶融押出しして網状体を形成する。溶融した燐含有熱可塑弾性樹脂は複数のオリフィスを持つ多列ノズルに供給し、オリフィスより下方へ吐出する。線条を複合化する場合は、多数の押出機より別々に溶融混練りした熱可塑性弾性樹脂を、多列ノズルのオリフィス直前で複合化するように分配合流させて下方に吐出する。ス−スコアではコア成分を中央から供給し、その回りからシ−ス成分を合流させて吐出する。サイドバイサイドでは左右または前後から各成分を合流させて吐出する。この時の溶融温度は、熱可塑性弾性樹脂の融点より１０℃〜８０℃高い温度である。（複合化される場合は高融点成分の融点より１０℃以上高く、低融点成分の融点より８０℃以下の同一の溶融温度が好ましい）熱可塑性弾性樹脂の融点より８０℃を越える高い溶融温度にすると熱分解が著しくなり熱可塑性弾性樹脂のゴム弾性特性が低下するので好ましくない。他方、熱可塑性弾性樹脂の融点より１０℃以上高くしないとメルトフラクチャ−を発生し正常な線条形成が出来なくなり、また、吐出後ル−プ形成しつつ接触させ融着させる際、線条の温度が低下して線条同士が融着しなくなり接着が不充分な網状体となる場合があり好ましくない。好ましい溶融温度は融点より２５℃から６０℃高い温度、より好ましくは融点より３０℃から４０℃高い温度である。オリフィスの形状は特に限定されないが、中空断面（例えば三角中空、丸型中空、突起つきの中空等となるよう形状）及び、又は異形断面（例えば三角形、Ｙ型、星型等の断面二次モ−メントが高くなる形状）とすることで前記効果以外に溶融状態の吐出線条が形成する３次元構造が流動緩和し難くし、逆に接触点での流動時間を長く保持して接着点を強固にできるので特に好ましい。特開平１−２０７５号公報に記載の接着のための加熱をする場合、３次元構造が緩和し易くなり平面的構造化し、３次元立体構造化が困難となるので好ましくない。網状体の特性向上効果としては、見掛けの嵩を高くでき軽量化になり、また抗圧縮性が向上し、弾発性も改良できへたり難くなる。中空断面では中空率が８０％を越えると断面が潰れ易くなるので、好ましくは軽量化の効果が発現できる１０％以上７０％以下、より好ましくは２０％以上６０％以下である。オリフィスの孔間ピッチは線状が形成するル−プが充分接触できるピッチとする必要がある。緻密な構造にするには孔間ピッチを短くし、粗密な構造にするには孔間ピッチを長くする。本発明の孔間ピッチは好ましくは３ｍｍ〜２０ｍｍ、より好ましくは５ｍｍ〜１０ｍｍである。本発明では所望に応じ異密度化や異繊度化もできる。列間のピッチ又は孔間のピッチも変えた構成、及び列間と孔間の両方のピッチも変える方法などで異密度層を形成できる。また、オリフィスの断面積を変えて吐出時の圧力損失差を付与すると、溶融した熱可塑性弾性樹脂を同一ノズルから一定の圧力で押し出される吐出量が圧力損失の大きいオリフィスほど少なくなる原理を使って長手方向の区間でオリフィスの断面積が異なる列を少なくとも複数有するノズルを用い異繊度線条からなる網状構造体を製造することができる。次いで、該ノズルより下方に向けて吐出させ、ル−プを形成させつつ溶融状態で互いに接触させて融着させ３次元構造を形成しつつ、接合した網状構造体両面を引取りネットで挟み込み、網状体の表面の溶融状態の曲がりくねった吐出線条を４５°以上折り曲げて変形させて表面をフラット化すると同時に曲げられていない吐出線条との接触点を接着して構造を形成後、連続して冷却媒体（通常は室温の水を用いるのが冷却速度を早くでき、コスト面でも安くなるので好ましい）で急冷して本発明の３次元立体網状構造体化した網状体を得る。ノズル面と引取り点の距離は少なくとも４０ｃｍ以下にすることで吐出線条が冷却され接触部が融着しなくなることを防ぐのが好ましい。吐出線条の吐出量５ｇ／分孔以上と多い場合は１０ｃｍ〜４０ｃｍが好ましく、吐出線条の吐出量５ｇ／分孔未満と少ない場合は５ｃｍ〜２０ｃｍが好ましい。網状体の厚みは溶融状態の３次元立体構造体両面を挟み込む引取りネットの開口幅（引取りネット間の間隔）で決まる。本発明では上述の理由から引取りネットの開口幅は５ｍｍ以上とする。次いで水切り乾燥するが冷却媒体中に界面活性剤等を添加すると、水切りや乾燥がしにくくなったり、熱可塑性弾性樹脂が膨潤することもあり好ましくない。尚、ノズル面と樹脂を固化させる冷却媒体上に設置した引取りコンベアとの距離、樹脂の溶融粘度、オリフィスの孔径と吐出量などにより所望のループ径や線径をきめられる。冷却媒体上に設置した間隔が調整可能な一対の引取りコンベアで溶融状態の吐出線条を挟み込み停留させることで互いに接触した部分を融着させつつ連続的に冷却媒体中に引込み固化させ網状構造体を形成する時、上記コンベアの間隔を調整することで、融着した網状体が溶融状態でいる間で厚み調節が可能となり、所望の厚みのものが得られる。コンベア速度も速すぎると、接触点の形成が不充分になったり、融着点が充分に形成されるまでに冷却され、接触部の融着が不充分になる場合がある。また、速度が遅過ぎると溶融物が滞留し過ぎ、密度が高くなるので、所望の見掛け密度に適したコンベア速度を設定する必要がある。かくして得られた網状体は、次いで、座席のクッション形態にあわせた形に打ち抜き、所定形状の切断された網状体を得る。網状体をクッション層に用いる場合、その使用目的、使用部位により使用する樹脂、繊度、ル−プ径、嵩密度を選択する必要がある。例えば、ソフトなタッチと適度の沈み込みと張りのある膨らみを付与するためには、低密度で細い繊度、細かいル−プ径にするのが好ましく、中層のクッション機能も発現させるには、共振振動数を低くし、適度の硬さと圧縮時のヒステリシスを直線的に変化させて体型保持性を良くし、耐久性を保持させるために、中密度で太い繊度、やや大きいル−プ径の層と低密度で細い繊度、細かいル−プ径の層を積層一体化した構造にするのが好ましい。また、樹脂製造過程以外でも性能を低下させない範囲で製造過程から成形体に加工し、座席化する任意の段階で難燃化、防虫抗菌化、耐熱化、撥水撥油化、着色、芳香等の機能付与を薬剤添加等の処理加工ができる。
他方樹脂成形体は、一般の公知の射出成形機を用いて熱可塑性弾性樹脂、又は熱可塑性非弾性樹脂、又はそれらの混合物、及び必要な改質剤、例えば難燃剤等を、例えば二軸押出機を用いて溶融混合した溶融樹脂を例えば第３図や第４図の形状となる金型内へ押し出し、冷却して射出成形体として得られる。樹脂押し出し時の金型の温度は、樹脂の融点から樹脂の融点より３０℃低い温度として、金型の壁面に離型剤を付与を少なくして、好ましくは付与しないで成形したものが、成形時の網状体との接着が強固となるので望ましい。
【００１７】
ついで、本発明の座席は、雌型に所定形状に切断されたクッション層となる網状体を配し、その上に裏面又は背面となる深絞り形状に成形された樹脂成形体を配し、又は網状体と樹脂成形体間に網状体の融点より少なくとも１０℃以上低い融点を持つ接着層を配して、雄型で上からクッション層を圧縮すると共に樹脂成形体を介して凹部内側からも凸部を圧縮し、網状体の融点より５℃高い温度〜融点より５０℃低い温度の加熱媒体で加熱して熱成形により一体化した後、一旦冷却するか、又は連続して、網状体のガラス転移温度より１０℃高い温度以上、融点より２０℃以上低い温度でアニ−リングして得たクッション成形体に側地を取付けて、座席フレ−ムに固定して得られる。以下、図面で成形方法を説明する。第５図（Ａ）に示すように、通気孔８を有する雌金型７に、所定の形状に切断した網状体２及び２’を乗せて、次いで第５図（Ｂ）に示す如く、開孔部４を有する樹脂成形体３をその上から乗せて、次いで、網状体２を樹脂成形体３の裏側まで巻き込み、樹脂成形体３の裏側にある網状体２を止めるフック９に引っ掛けて網状体２をとめる。次いで、第５図（Ｃ）の如く、通気孔８を有する雄金型１０で圧縮する。雄金型１０で上から圧縮することで樹脂成形体３の凸部３’が網状体２の内側から網状体２の外側へ圧縮力を伝え、雌金型７の形状にきれいに添う形状に圧縮される。次いで、加熱流体を矢印の方向から通じて全体を加熱し、熱成形する。このときの加熱流体の温度は網状体の一部が塑性緩和して座席の形状に変形し、樹脂成形体が塑性変形しない温度で、樹脂成形体と網状体が熱接着できる温度に加熱する。例えば、（例１）網状体が単一組成の場合、網状体の融点より５℃高い温度で加熱し、網状体の線条の表面を溶融させて樹脂成形体と熱接着させる。網状体の融点より１０℃以上高くすると網状体の形状が崩れてクッション機能が低下するので好ましくない。網状体がシ−スコア構造の線条からなる場合、例えば、（例２）シ−ス成分の融点より５℃以上高い温度から網状体のコア成分の融点より５℃高い温度で熱成形することで、網状体構造を保持して、所望の座席形状に形成出来、且つ、樹脂成形体との熱接着が強固にできる好ましい事例である。コア成分が塑性変形しない温度、例えば、融点より６０℃以上低い温度では所望の座席形状に形成出来なくなるので好ましくない。例えば、網状体が単一組成で、接着剤を用いる場合、（例３）第５図（Ｂ）にセットする前に予め接着剤を樹脂成形体３の表面に塗布するか、又は（例４）第６図に示すように熱接着不織布１２を積層して熱成形する場合にも、例えば接着剤の融点が１６０℃の熱可塑性弾性樹脂からなる樹脂又はメルトブロー不織布１２、網状体２及び２’の融点が２２０℃の場合、加熱温度は１７０℃以上、２２５℃以下が好ましい。（例５）第６図は、本発明の実施形態の一例のワディング層１１にファイバ−フィルを用いた場合であるが、例えばポリエステル系熱可塑性弾性樹脂を熱接着成分としたファイバ−フィルウエッブの熱接着成分の融点が１８５℃で、ファイバ−フィルウエッブの母材が融点２６５℃のＰＥＴで、接着剤のメルトブロー不織布１２が１６０℃で網状体２及び２’の融点が２２０℃の場合は、熱接着成分の融点の高いほうの１８５℃より１０℃高く、網状体の融点より５℃高い温度、即ち、１９５℃から２２５℃で熱成形するのが好ましい。昇温時間は１５分以内にしないと低融点成分の熱分解が促進され接着機能が低下したり、生産性が低下するので好ましくない。好ましくは、１０分以内、より好ましくは５分以内に加熱温度まで昇温し、１分から５分程度加熱温度を保持し成形して、ついで冷却する。本発明の好ましい方法としては、連続して、又は一旦冷却後、一体成形して製品化に至る任意の工程で熱可塑性弾性樹脂のガラス転移点温度より１０℃高い温度以上、融点より少なくとも１０℃以下の温度でアニ−リングよる疑似結晶化処理を行うのがより好ましい製法である。疑似結晶化処理温度は、少なくとも融点（Ｔｍ）より１０℃以上低く、ハ−ドセグメントのガラス転移点温度であるＴａｎδのα分散立ち上がり温度（Ｔαｃｒ）以上で行う。この処理で、融点以下に吸熱ピ−クを持ち、疑似結晶化処理しないもの（吸熱ピ−クを有しないもの）より耐熱耐へたり性が著しく向上する。本発明の好ましい疑似結晶化処理温度は（Ｔαｃｒ＋１０℃）から（Ｔｍ−２０℃）である。連続してアニ−リングする場合、例えば、例１ではガラス転移点温度＋１０℃以上、融点より２０℃以上低い温度まで冷却して、５分以上その温度を保持後、５０℃未満まで冷却して金型からクッション体を取り出す。例１では、網状体の融点が２２０℃でガラス転移点温度が５０℃とすると、６０℃以上、好ましくは１００℃から２００℃未満、好ましくは１５０℃未満で５〜１０分加熱状態を保持するのが良い。例２では、シース成分の融点より２０℃以上低い温度からコア成分のガラス転移点温度、例えばシ−ス成分の融点が１８５℃、コア成分のガラス転移点温度が５０℃の場合は、６０℃以上、好ましくは１００℃以上、１６５℃以下、好ましくは１３０℃以下の温度でアニ−ルするのが良い。例３、例４、例５では、同様に６０℃以上、好ましくは１００℃以上、１４０℃以下、好ましくは１３０℃以下でアニ−ルするのが良い。一旦冷却後、非連続してアニ−ルすることで同様の効果が発現する。かくして、単なる熱処理により疑似結晶化させても耐熱耐へたり性がより向上したクッション体を得る。が更には、別途、１０％以上の圧縮変形を付与してアニ−リングすることで耐熱耐へたり性が著しく向上するのでより好ましい。かくして得られたクッション体は、側地１を被せて、好ましくは難燃性の側地、例えば東洋紡績（株）製の難燃性ポリエステル繊維ハイムを用いたポリエステルモケットを被せてクッション体に添わせてクッション体の裏側で側地を止めると共に、クッション表面に側地１を添わして、クッション体の凹部より、例えば、実開昭５６−１０１０７１号公報、実開昭６０−１０９４９９号公報等に開示された引込みボタン等で樹脂成形体３を貫通させて側地を吊り込み、又は、公知の吊り込み方法、例えば予め雌金型７の凸部に吊り込みジグをセットして熱成形後、クッション体凹部より樹脂成形体３又は、補強フレ−ム６部分で固定して側地１をクッション体に添わせて固定する方法も採用できる。次いで座席のセットフレ−ムに固定して本発明の座席が得られる。
【００１８】
本発明の座席は、回復性と振動吸収性の良い熱可塑性弾性樹脂からなる網状体をクッション層に用い、多孔質の樹脂成形体が従来のクッション体での深絞り成形部を構成して、通気性を良くし、凸部の芯材効果も果たし、且つクッション体の形態保持性を向上させているので、自動車や鉄道車両用の座席に最適な、振動遮断性、耐熱耐久性、形態保持性、クッション性の優れた、蒸れにくく、難燃性を有し、燃焼ガスの毒性指数が低い、安全性の高い座席である。また、従来公知のファイバ−フィルを用いたクッション体では、深絞り成形が困難で、成形が煩雑になっているが本発明の方法では、深絞り成形を省略して一段で成形加工ができるため、成形加工のコストダウンが図れ安価に有用な座席を提供できる。車両用以外に船舶用、事務用、家具用等の座席にも勿論有用である。
【００１９】
【実施例】
以下に実施例で本発明を詳述する。
【００２０】
なお、実施例中の評価は以下の方法で行った。
１．融点（Ｔｍ）および融点以下の吸熱ピ−ク
島津製作所製ＴＡ５０，ＤＳＣ５０型示差熱分析計を使用し、昇温速度２０℃／分で測定した吸発熱曲線から吸熱ピ−ク（融解ピ−ク）温度を求めた。
２．Ｔαｃｒ
ポリマ−を融点＋１０℃に加熱して、厚み約３００μｍのフイルムを作成して、オリエンテック社製バイブロンＤＤＶＩＩ型を用い、１１０Ｈｚ、昇温速度１℃／分で測定したＴａｎδ（虚数弾性率Ｍ”と弾性率の実数部分Ｍ’との比Ｍ”／Ｍ’）のゴム弾性領域から融解領域への転移点温度に相当するα分散の立ち上がり温度。
３．見掛け密度
試料を１５ｃｍ×１５ｃｍの大きさに切断し、４か所の高さを測定し、体積を求め試料の重さを体積で徐した値で示す。（ｎ＝４の平均値）
４．線条の繊度
試料を１０箇所から各線条部分を切り出し、アクリル樹脂で包埋して断面を削り出し切片を作成して断面写真を得る。各部分の断面写真より各部の断面積（Ｓｉ）を求める。また、同様にして得た切片をアセトンでアクリル樹脂を溶解し、真空脱泡して密度勾配管を用いて４０℃にて測定した比重（ＳＧｉ）を求める。ついで次式より線状の９０００ｍの重さを求める。（単位ｃｇｓ）
繊度＝〔（１／ｎ）ΣＳｉ×ＳＧｉ〕×９０００００
５．融着
試料を目視判断で融着しているか否かを接着している繊維同士を手で引っ張って外れないか否かで外れないものを融着していると判断する。
６．耐熱耐久性（７０℃残留歪）
試料を１５ｃｍ×１５ｃｍの大きさに切断し、５０％圧縮して７０℃乾熱中２２時間放置後冷却して圧縮歪みを除き１日放置後の厚み（ｂ）を求め、処理前の厚み（ａ）から次式、即ち（ａ＋ｂ）／ａ×１００より算出する。単位％（ｎ＝３の平均値）
７．繰返し圧縮歪
試料を１５ｃｍ×１５ｃｍの大きさに切断し、島津製作所製サ−ボパルサ−にて、２５℃６５％ＲＨ室内にて５０％の厚みまで１Ｈｚのサイクルで圧縮回復を繰り返し２万回後の試料を１日放置後の厚み（ｂ）を求め、処理前の厚み（ａ）から次式、即ち（ａ＋ｂ）／ａ×１００より算出する。単位％（ｎ＝３の平均値）
８．燃焼ガスの毒性指数
ＪＩＳ−Ｋ−７２１７の方法で測定した各燃焼ガス量（ｍｇ）を１０分間吸入した時の致死量（ｍｇ／１０リットル）で除した値の積算値で示す。
９．座り心地
３０℃ＲＨ７５％室内で、本発明の方法により作成した座席、又は比較の方法で作成した座席にパネラ−を座らせ以下の評価をおこなった。（ｎ＝５）
（１）床つき感：座ったときの「どすん」と床に当たった感じの程度を感覚的に定性評価した。感じない；◎、殆ど感じない；○、やや感じる；△、感じる；×
（２）蒸れ感：２時間座っていて、臀部やふと股の内側の座席と接する部分が蒸れた感じを感覚的に定性評価した。殆ど感じない：◎、僅かに蒸れを感じる；○、やや蒸れを感じる；△、蒸れを著しく感じる；×
（３）８時間以内でどの程度我慢して座席に座っていられるか：１時間以内；×、２時間以内；△、４時間以内；○、４時間以上；◎
（４）４時間座席に座らせたときの腰の疲れ程度を感覚的に定性評価した。無し；◎、殆ど疲れない；○、やや疲れる；△、非常に疲れる；×
（５）総合評価：（１）から（４）までの評価の◎を４点、○を３点、△を２点、×を１点として１２点以上で△を含まないもの；非常に良い（◎）、１２点以上で△を含むもの；良い（○）、１０点以上で×を含まないもの；やや悪い（△）、×を含むもの；悪い（×）として評価した。
１０．耐久性
作成した座席（座部及び背部）の中央、及びサイドに直径１０ｃｍの平板で６０ｋｇの圧縮力で繰り返し圧縮できる装置にて、０．５Ｈｚのサイクルで１００回繰り返し圧縮させて、座席のへたり程度を以下の基準で判定した。◎：へたりなし。○：へたり軽度。△：少しへこみがあり、側地のたるみが出てへたりが判る。×：へこみが大きく目立ちへたりが著しい。（ｎ＝３の平均値）
【００２１】
実施例１
ポリエステル系エラストマ−として、ジメチルテレフタレ−ト（ＤＭＴ）又は、ジメチルナフタレ−ト（ＤＭＮ）と１・４ブタンジオ−ル（１・４ＢＤ）を少量の触媒と仕込み、常法によりエステル交換後、ポリテトラメチレングリコ−ル（ＰＴＭＧ）を添加して昇温減圧しつつ重縮合せしめポリエ−テルエステルブロック共重合エラストマ−を生成させ、次いで抗酸化剤２％を添加混合練込み後ペレット化し、５０℃４８時間真空乾燥して得られた熱可塑性弾性樹脂原料の処方を表１に示す。
【００２２】
【表１】

【００２３】
幅５０ｃｍ、長さ５ｃｍのノズル有効面に幅方向の孔間ピッチ１０ｍｍ、長さ方向の孔間ピッチ５ｍｍの千鳥配列としたオリフィス形状は外径２ｍｍ、内径１．６ｍｍでトリプルブリッジの中空形成性断面としたノズルに、得られたＡ−１及びＡ−２を、２本の混練り機能をもつ押出機にて、別々に定量供給しつつ、難燃剤として既存化学物質番号（３）−３７３５を燐含有量１００００ｐｐｍとなるように添加して溶融混練りし、Ａ−１とＡ−２をオリフィス直前でＡ−１をシ−ス成分に、Ａ−２をコア成分となるように（シ−ス／コア：５０／５０重量比）オリフィス背面に分配し、２４５℃にて単孔当たりの吐出量２．０ｇ／分にてノズル下方に吐出させ、ノズル面１０ｃｍ下に冷却水を配し、幅６０ｃｍのステンレス製エンドレスネットを平行に５ｃｍ間隔で一対の引取りコンベアを水面上に一部出るように配して、両面を挟み込みつつ毎分１ｍの速度で２５℃の冷却水中へ引込み固化させ、次いで水切り処理した後、所定の大きさに切断して得られた網状体２の特性を表２に示す。実施例１に用いる網状体は断面形状がシースコア構造の三角おむすび型中空断面で中空率が４０％、繊度が９０００デニ−ル、燐含有量１００００ｐｐｍ（６０Ａ＋２００＝２７８０ｐｐｍ）の線条で形成しており、平均の見掛け密度が０．０４５ｇ／ｃｍ^３であった。この網状体は柔らかい弾性樹脂の特性が生かせた網状構造のため耐熱性、常温での耐久性に優れたクッション機能を有し、難燃性で燃焼ガスの毒性指数も低い安全性の高いクッション層であった。
【００２４】
【表２】

【００２５】
ポリエチレンテレフタレ−ト９５部とＡ−１を５部とを混合乾燥して、押出機に供給し２７５℃で溶融混練りし、全面にφ４ｍｍの開孔部を有するようにした背部および座部用樹脂成形体金型に、余熱温度２６０℃として、混練り溶融した熱可塑性樹脂を注入して冷却後取り出し得られた樹脂成形体３は、開孔率が３６％であった。
【００２６】
相対粘度１．２のＰＢＴと極限粘度０．５８のＰＥＴとを中空Ｃ型オリフィス直前に２８５℃にて、サイドバイサイドに分配して吐出させ、常法にて未延伸糸を紡糸し、次いで、延伸した繊維に、機械巻縮を付与後、乾熱１６５℃にて立体巻縮を発現させて５１ｍｍに切断し、繊度が１３デニ−ル、巻縮度が３５％、巻縮数が２３山／インチ、中空率２８％の丸断面で立体巻縮を有するファイバ−フィルウエッブの母材を得た。Ａ−１をシ−ス成分、Ａ−２をコア成分にして、２６０℃にて吐出し、紡糸速度３５００ｍ／分にて作成した繊維を２万デニ−ルに合糸してクリンパ−にて機械巻縮を付与後５１ｍｍに切断して、繊度が５デニ−ル、乾熱１６０℃の収縮率が８％、断面形状がシ−ス・コアの中実丸断面の熱接着繊維を得た。得られた母材６０部と熱接着繊維４０部を常法により混繊してカ−ドウエッブを作成し、積層してニ−ドルパンチして所定の大きさに切断した厚み１０ｍｍのファイバ−フィルウエッブ１１を作成した。
【００２７】
Ａ−１を２４０℃にて溶融し、２８０℃の加熱空気にて常法により目付け３０ｇ／ｍ^２、繊度０．０５デニ−ルの繊維同士が融着したメルトブロ−不織布１２を得た。
【００２８】
第６図（Ａ）に示すように、雌金型にファイバ−フィルウエッブ１１と網状体２及び２’を積層して、層間にメルトブロ−不織布１２を積層した上に、第６図（Ｂ）に示すように、樹脂成形体３を乗せて押さえ込み、ファイバ−フィルウエッブ１１、網状体２、メルトブロ−不織布１２を樹脂成形体３の裏側まで折り返してフック９に引っ掛けて止め、次いで、第６図（Ｃ）に示すように、雄金型１０で押さえて圧縮し、２００℃の加熱空気にて強制貫通させ、５分間で加熱昇温させ、２分間その温度を保持後、加熱空気を１３０℃に下げて冷却アン−リングを１０分間行い、冷却して熱成形された、座部のクッション層の平均見掛け密度が０．０５８ｇ／ｃｍ^３、背部のクッション層の平均見掛け密度が０．０５５ｇ／ｃｍ^３のクッション体を得た。次いで、ジメチルテレフタル酸と１０〔２・３・ジ（２・ヒドロキシエトキシ）−カルボニルプロピル〕９・１０・ジヒドロ・９・オキサ・１０ホスファフェナレンス・１０オキシロを燐含有量で５０００ｐｐｍとなる量と、グリコ−ル成分にＤＥＧを少量の触媒と仕込み、常法によりエステル交換後、昇温減圧しつつ重縮合せしめて得た共重合ＰＥＴを常法により繊維化した２デニ−ルのステ−プルを用い、常法により得たポリエステル繊維からなる目付け４５０ｇ／ｍ^２、通気度９０ｃｃ／ｃｍ^２・秒のモケットの側地１でクッション体の表面を被い、裏側に引っ張って側地を張りながら樹脂成形体に止めると共に、サイドと中央の間の凹部を返しの付いた引込みボタンで樹脂成形体３を貫通させて側地を吊り込み、補強フレ−ムを樹脂成形体と固定して。裏面又は背面を裏張して、車両に固定するフレ−ムに固定して第１図に示す様な座席を作成した。表２に示す如く得られた座席の座り心地は良好で、耐久性も実用使用に耐えるものであった。座席の端を火炎に曝すと側地やワディング層と共に網状体も燃え始めるとドリップになり火炎の広がりは抑制されすぐに消炎した。難燃性の良好な素材を用いた場合は、火災時も安全性が確保できる例である。
【００２９】
実施例２
ジメチルイソフタレ−ト（ＤＭＩ）２０モル％とＤＭＴ８０モル％及び１・４ブタンジオ−ル（１・４ＢＤ）を少量の触媒と仕込み、実施例１の方法と同様にして得たポリエステル系熱可塑性弾性樹脂の処方を表１に示す。Ａ−３をオリフィスの孔形状を孔径φ１ｍｍの丸断面としたノズルを用いた以外実施例１と同様にして得た網状体の特性を表−２に示す。なお、中実丸断面の繊度が９０００デニ−ル、の線条から形成されており、網状体の平均の見掛け密度が０．０４３ｇ／ｃｍ^３であった。次いで、実施例１と同様にして作成した、座部のクッション層の平均見掛け密度が０．０５６ｇ／ｃｍ^３、背部のクッション層の平均見掛け密度が０．０５３ｇ／ｃｍ^３のクッション体を用いて得た座席の評価結果を表２に併記する。表２で明らかなごとく、網状体の耐熱性と常温での耐久性は実用上使用可能で、燃焼ガスの毒性指数も低い安全性の高いクッション材であり、作成した座席は、座り心地の優れたクッション機能を有し、耐久性も実用使用が可能なものであることが判る。
【００３０】
実施例３
ポリウレタン系エラストマ−として、４・４’ジフェニルメタンジイソシアネ−ト（ＭＤＩ）とＰＴＭＧ及び鎖延長剤として１・４ＢＤを添加して重合し次いで抗酸化剤２％を添加混合練込み後ペレット化し真空乾燥してポリエ−テル系ウレタンポリマ−の処方を表３に示す。
【００３１】
【表３】

【００３２】
得られた熱可塑性弾性樹脂Ｂ−１を溶融温度２２０℃とした以外実施例１と同様にして得た網状体の特性を表２に示す。実施例３はクッション層の網状体の線条は断面形状が三角おむすび型の中空断面で中空率は４１％、繊度が９８００デニ−ルの線条から形成されており、平均の見掛け密度が０．０４５ｇ／ｃｍ^３の耐熱性、常温での耐久性ともに優れたクッション機能を有し、燃焼ガスの毒性指数も低い網状体であった。次いで、流動開始温度が１３５℃の熱可塑性ポリウレタフイルムを接着剤１２として用い、ファイバ−フルウエッブを使用しなかった以外実施例１と同様に積層圧縮し、熱成形温度を１７２℃とし、アニーリング温度を８０℃とした以外実施例１と同様にして成形した、座部のクッション層の平均見掛け密度が０．０６０ｇ／ｃｍ^３、背部のクッション層の平均見掛け密度が０．０５６ｇ／ｃｍ^３のクッション体を用いて得た実施例３の座席は、柔らかいウレタンの特性を生かした座り心地が優れ、耐久性も実用使用に耐える優れた座席であることが判る。
【００３３】
比較例１
相対粘度１．２０のポリブチレンテレフタレ−ト（ＰＢＴ）を溶融温度２７０℃とした以外、実施例２と同様にして得た線条の繊度が比較例１は８８００デニ−ル、見掛け密度が０．０４４ｇ／ｃｍ^３の網状体の特性を表２に示す。次いで、熱成形温度を２５０℃とし、疑似結晶化の為のアニ−リングをしなかった以外、実施例２と同様にして作成した座部のクッション層の平均見掛け密度が０．０５５ｇ／ｃｍ^３、背部のクッション層の平均見掛け密度が０．０５２ｇ／ｃｍ^３のクッション体を用いて得た比較例１の座席は、元々耐熱耐久性が悪い熱可塑性非弾性ポリエステルからなる網状体をクッション層に使用しているため、硬くて座り心地が悪く、耐久性も悪い座席となった例である。
【００３４】
比較例２
樹脂成形体及びファイバ−フィルウエッブを用いないで、実施例２で作成した網状体のみを用いて座部のクッション体の平均見掛け密度が０．０６２ｇ／ｃｍ^３、背部のクッション体の平均見掛け密度が０．０５６ｇ／ｃｍ^３となるように積層圧縮して熱成形し、アニ−リングしないで急速に冷却した以外、実施例２と同様にして作成したクッション体は、樹脂成形体を使用しないためサイド部の凸状形状の表面仕上がりが不良となり、表２に示す得られた座席の特性も、座り心地は良好だが、耐久性が劣り座席としては好ましくない例である。
【００３５】
比較例３
網状体を用いずに、実施例１で作成したファイバ−フィルウエッブのみをクッション層に用いて、クッション層の平均見掛け密度が０．０６２ｇ／ｃｍ^３、背部のクッション体の平均見掛け密度が０．０５６ｇ／ｃｍ^３となるように積層圧縮して熱成形し、アニ−リングしないで急速に冷却した以外、実施例２と同様にして作成したクッション体を用いて作成した、表２に示す座席の特性は、座り心地は良好だが、耐熱耐久性の優れた熱可塑性弾性樹脂からなる網状体を使用しないため、耐久性が劣り座席としては好ましくない例である。
【００３６】
比較例４
１８０ｇ／分の吐出量で、ノズル面下５ｃｍに引取りコンベアネットを配して引取り速度１．２ｍ／分にて引取った以外、実施例２と同様にして得た繊度が１８００デニ−ル、燐含有量が９０００ｐｐｍ（６０Ａ＋２００＝３３２０ｐｐｍ）、平均の見掛け密度が０．００６ｇ／ｃｍ^３の網状体を用いて、座部及び背部のクッション層の見掛け密度が０．００９ｇ／ｃｍ^３となるように積層圧縮し、疑似結晶化処理をしなかった以外実施例２と同様にして得たクッション体を用いた座席は、密度が低すぎて座り心地が著しく劣り、耐久性も劣る座席の例である。
【００３７】
比較例５
単孔当たりの吐出量３ｇ／分にて吐出させ、引取りコンベアネットの速度を０．３ｍ／分とした以外実施例２と同様して得た線条繊度が１３０００デニ−ルで、平均見掛け密度が０．２１ｇ／ｃｍ^３の網状体を用い、座部及び背部のクッション層の密度が０．２５ｇ／ｃｍ^３となるように積層圧縮して熱成形し、アニ−リングしないで急速に冷却した以外、実施例２と同様にして作成したクッション体を用いて得た座席は、クッション層が硬いため座り心地がやや劣り、耐久性が不充分な例である。
【００３８】
比較例６
幅５０ｃｍ、長さ５ｃｍのノズル有効面に幅方向の孔間ピッチ１０ｍｍ、長さ方向の孔間ピッチ２０ｍｍの千鳥配列としたオリフィス径φ２ｍｍとしたノズルを用いて単孔当たりの吐出量２５ｇ／分にて吐出させて、ノズル面３０ｃｍ下に引取りコンベアネットを配して１ｍ／分にて引き取った以外、比較例２と同様にして得た線条の繊度は１１３０００デニ−ルで平均見掛け密度が０．１５ｇ／ｃｍ^３の網状体を用いて、座部及び背部のクッション層の見掛け密度が０．０３５ｇ／ｃｍ^３となるように積層圧縮し、疑似結晶化処理をしなかった以外実施例２と同様にして得たクッション体を用いた座席は、網状体の線条繊度が著しく太く密度斑があるため、耐久性が悪くなり、座り心地もやや悪くなる座席の例である。
【００３９】
比較例７
ノズル面６０ｃｍ下に引取りコンベアネットを配して引き取ったあと疑似結晶化処理をしなかった以外、実施例２と同様の方法で得た網状体の特性の一部を表２に示す。なお、接着状態が不良で形態保持が悪いため、５０％圧縮時反発力、見掛け密度、補強効果、７０℃残留歪、繰返圧縮歪みの評価はしていない。次いで、この線条がばらばらの網状体を雌金型に詰め込み、クッション層の見掛け密度が０．０５５ｇ／ｃｍ^３となるように積層圧縮し、疑似結晶化処理をしなかった以外実施例２と同様にして得たクッション体を用いた座席は、網状体の線条が融着していないので座り心地が悪く、網状形態が固定されていないのでクッション材の損傷が大きくなり耐久性も劣る例である。
【００４０】
比較例８
実施例２で得た網状体を用い、実施例１で用いた樹脂成形体の表面にシリコ−ン油膜を塗布し、接着剤を用いないでクッション層の見掛け密度が０．０５５ｇ／ｃｍ^３となるように積層圧縮し、疑似結晶化処理をしなかった以外実施例２と同様にして得た樹脂成形体と網状体が接合一体化されていないクッション体を用いて作成した座席は、座り心地は悪くないが、耐久性が劣る座席であった。
【００４１】
【発明の効果】
本発明の座席は、回復性と振動吸収性の良い熱可塑性弾性樹脂からなる線条が融着一体化した網状体をクッション層に用い、多孔質の樹脂成形体が従来のクッション体での深絞り成形部を構成してクッション層と接合一体化しているため、通気性を良くし、凸部の耐久性とクッション体の形態保持性を向上させているので、自動車や鉄道車両用の座席に最適な、振動遮断性、耐熱耐久性、形態保持性、クッション性の優れた、蒸れにくく、分別せずにリサイクルが可能な座席である。また、従来公知のファイバ−フィルを用いたクッション体では、深絞り成形が困難で、成形が煩雑になっているが本発明の方法では、深絞り成形を省略して一段で成形加工ができるため、成形加工のコストダウンが図れ安価に有用な座席を提供できる。車両用以外に船舶用、事務用、家具用等の座席にも勿論有用である。
【図面の簡単な説明】
【図１】本発明座席の縦断面概念図を示す。
【図２】本発明座席の背部及び座部の横断面概念図を示す図である。
【図３】本発明座席の背部に用いる樹脂成形体の斜視図である。
【図４】本発明座席の座部に用いる樹脂成形体の斜視図である。
【図５】本発明座席の成形加工工程の概念を示す図であり（Ａ）→（Ｂ）→（Ｃ）の順に工程は進行する。
【図６】本発明座席の成形加工工程の概念を示す図であり、（Ａ）→（Ｂ）→（Ｃ）の順に工程は進行する。
【符号の説明】
１：側地２：網状体
３：樹脂成形体４：樹脂成形体の開孔部
５：裏張り部６：補強フレ−ム
７：雌金型１０：雄金型
１１：ファイバ−フィルウエッブ１２：接着剤層、[0001]
[Industrial applications]
The present invention relates to a vehicle seat having excellent cushioning properties, heat resistance and vibration absorption, and a method of manufacturing a recyclable vehicle seat and a seat capable of omitting deep drawing when molding a cushion molded body.
[0002]
[Prior art]
At present, in a vehicle seat, resin cushion or hard cotton to which urethane foam or crimped fiber is adhered is used for a cushion layer.
[0003]
However, seats with urethane foam cushion layer are extremely durable, but are inferior in moisture and water permeability and have heat storage properties, so they are easy to humid, and because they are not thermoplastic, they are difficult to recycle. Furnace damage is large and toxic gas removal is expensive. For this reason, landfills have been increased, but it is difficult to stabilize the ground. In addition, the moldability is excellent, but there is also a problem of pollution of chemicals used during production. Japanese Unexamined Patent Publication (Kokai) No. 63-77482 has been proposed as a method for improving stuffiness, but it is insufficient.
[0004]
Japanese Patent Application Laid-Open Nos. 60-11352 and 61-61, as a seat with improved stuffiness, use a resin cotton in which a polyester fiber is bonded to a cushion layer with a rubber or urethane adhesive, for example, a rubber using an adhesive. And Japanese Patent Application Laid-Open No. 61-141391. Japanese Patent Application Laid-Open (JP-A) No. 61-137732 discloses a method using a crosslinkable urethane. Seats using these cushion layers are inferior in durability, are not thermoplastic, cannot be recycled because they are not of a single composition, and are cumbersome at the time of processing. There is a problem that gets worse. There is also a problem of pollution of chemicals used during manufacturing.
[0005]
JP-A-5-208470 and JP-A-5-220278 use polyester hard cotton that is made of a thermo-adhesive fiber as an adhesive so that it can be recycled and generate less toxic combustion gas in the event of a fire. JP-A-5-247815, JP-A-5-269264, JP-A-5-329937 and the like have been proposed, but an amorphous polymer in which the adhesive component of the heat-bonding fiber used is brittle. However, there is a problem in that the bonding portion is brittle, and the bonding portion is easily destroyed during use, and the form and the elasticity are deteriorated. As an improved method, a method of entanglement treatment is proposed in Japanese Patent Application Laid-Open No. Hei 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is greatly reduced. In addition, there is a problem that the bonded portion is hardly deformed and it is difficult to provide a soft cushioning property. Incidentally, it is difficult to perform deep drawing by these methods. As a method for improving the durability, a cushion material formed of polyester hard cotton using a heat-bonding fiber using a non-elastic polyester as a core component, using a polyester elastomer whose adhesive portion is soft and recovers even if deformed to some extent. Have been proposed in WO-91 / 19032, JP-A-5-163654, JP-A-5-337258, and the like. The polyester hard cotton disclosed in WO-91 / 19032 contains an amorphous component in an elastomer, and forms an amoebically-shaped bonded portion by improving the formation of a heat-bonded portion, but is easily plastically deformed. In addition, since the core component is an inelastic polyester, there is a problem that plastic deformation particularly under heating becomes remarkable, and heat resistance and compression resistance are lowered. As a method for improving these, Japanese Patent Application Laid-Open No. 5-163654 proposes a structure comprising only a polyester elastomer containing isophthalic acid as a sheath component and a heat-adhesive conjugate fiber using an inelastic polyester as a core component. However, the plastic deformation under heating is remarkable for the above-mentioned reason, and the heat resistance and the compression resistance are deteriorated. Therefore, there is a problem in using it as a cushion material for a vehicle seat. On the other hand, in JP-A-5-337258, the heat resistance and durability are improved because the elastomer does not contain an amorphous component, and the heat resistance and durability are further improved by annealing. Because of this, the durability is still insufficient as compared with foamed polyurethane. In addition, since the fibers are thermoformed, there is a problem that the complexity at the time of molding is not solved.
[0006]
A thermoplastic olefin network used for civil engineering is disclosed in JP-A-47-44839. However, since the material is an olefin, the heat resistance and durability are extremely poor and cannot be used as a cushion material for a vehicle seat. JP-A-1-207462 discloses a floor mat made of vinyl chloride. However, it has poor compression recovery at room temperature and remarkably poor heat resistance, so that it is preferable as a cushion material for a vehicle seat. Not something. Note that the net structure does not take into consideration any flame retardancy, vibration damping, and molding processing.
[0007]
[Problems to be solved by the invention]
Solving the above problems, isolating vibration, using a heat-resistant and durable thermoplastic elastic resin mesh with excellent heat retention, shape retention and cushioning properties, low flammability, low combustion gas toxicity index and high safety It is an object of the present invention to provide a vehicle seat and a manufacturing method that simplifies deep drawing.
[0008]
[Means for Solving the Problems]
Means for solving the above-mentioned problems, that is, the present invention is a seat comprising a back portion and a seat portion formed by a side ground, a cushion layer, and a back side deep drawing shape portion as a main portion, and the seat back side deep drawing shape portion is provided. The cushion layer was made of an injection-molded resin molded product having an opening ratio of 10% or more, and continuous lines having a fineness of 100,000 denier or less were meandered and brought into contact with each other, and most of the contact portions were fused. The apparent density of the thermoplastic elastic resin forming the three-dimensional structure is 0.01 g / cm. ³ From 0.2g / cm ³ A seat, characterized in that the resin molded body and the net are integrally joined, a net serving as a cushion layer cut into a predetermined shape in a female mold is disposed thereon, Placing a resin molded body formed in a deep drawing shape to be the back surface or the back surface, or arranging an adhesive layer having a melting point at least 10 ° C. lower than the melting point of the mesh body between the mesh body and the resin molded body, a male mold Then, the cushion layer is compressed from above and the convex part is also compressed from the inside of the concave part through the resin molded body, and heated with a heating medium at a temperature 5 ° C. higher than the melting point of the net-like body to 50 ° C. lower than the melting point. And then cooled or continuously annealed at a temperature of at least 10 ° C. higher than the glass transition temperature of the reticulated body and at least 20 ° C. lower than the melting point of the reticulated body. And secure it to the seat frame. Which is the process of seat which is characterized.
[0009]
The thermoplastic elastic resin in the present invention means a polyether-based glycol, a polyester-based glycol, a polycarbonate-based glycol or a long-chain hydrocarbon terminal having a molecular weight of 300 to 5000 as a soft segment. Examples thereof include polyester-based elastomers, polyamide-based elastomers, polyurethane-based elastomers, and polyolefin-based elastomers obtained by block-copolymerizing an olefin compound having an acid or a hydroxyl group. By using a thermoplastic elastic resin, regeneration becomes possible by re-melting, so that recycling becomes easy. For example, as the polyester-based elastomer, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylenediol as a soft segment, or a polyester ester having an aliphatic polyester as a soft segment is used. A block copolymer can be illustrated. More specific examples of polyester ether block copolymers include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid, and diphenyl 4.4 4 'dicarboxylic acid. Alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic dimer acid, and at least one dicarboxylic acid selected from ester-forming derivatives thereof; Species and aliphatic diols such as 1.4 butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, and 1.1 cyclohexane Alicyclic diols such as dimethanol and 1,4-cyclohexane dimethanol, or these And at least one diol component selected from ester-forming derivatives of polyethylene glycol, polypropylene glycol, polytetramethylene glycol and ethylene oxide-propylene oxide having an average molecular weight of about 300 to 5,000. It is a triblock copolymer composed of at least one of polyalkylenediols such as polymers. The polyester ester block copolymer is a ternary block copolymer composed of at least one of the above dicarboxylic acids and at least one of diols and polyester diols such as polylactone having an average molecular weight of about 300 to 5,000. . In consideration of thermal adhesion, hydrolysis resistance, stretchability, heat resistance, etc., terephthalic acid or naphthalene 2.6 dicarboxylic acid as a dicarboxylic acid, 1.4 butanediol as a diol component, poly As the alkylenediol, a triblock copolymer of polytetramethylene glycol or a terpolymer of polyester is particularly preferable. In a special case, those incorporating a polysiloxane-based soft segment can also be used. The thermoplastic elastomer resin of the present invention also includes the above-mentioned elastomer blended with a non-elastomer component, copolymerized product, and polyolefin-based component made into a soft segment. The polyamide-based elastomer has a hard segment of nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, or the like or a copolymerized nylon thereof, and the soft segment has an average molecular weight of about 300. Block copolymer composed of at least one of polyethylene glycol, polypropylene glycol, polytetramethylene glycol, polyalkylenediol such as ethylene oxide-propylene oxide copolymer, or You may mix and use two or more types. Further, those in which a non-elastomer component is blended or copolymerized can be used in the present invention. Examples of the polyurethane elastomer include (A) a polyether and / or polyester having a hydroxyl group at the terminal having a number average molecular weight of 1,000 to 6,000 and (B) in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.). A typical example is a polyurethane elastomer obtained by reacting a polyisocyanate having an organic diisocyanate as a main component with a prepolymer having both ends having isocyanate groups and a chain extending with a polyamine having a diamine as a main component (C). Can be exemplified. Examples of the polyesters and polyethers (A) include polybutylene adipate copolymerized polyesters having an average molecular weight of about 1,000 to 6,000, preferably 1,300 to 5,000, polyethylene glycol, polypropylene glycol, and polytetramethylene. Polyalkylenediols such as glycols and glycols comprising ethylene oxide-propylene oxide copolymers are preferred. As the polyisocyanate (B), conventionally known polyisocyanates can be used. An isocyanate mainly composed of 4,4'-diisocyanate is used, and if necessary, a conventionally known triisocyanate may be added in a small amount. As the polyamine (C), known diamines such as ethylenediamine and 1.2-propylenediamine are mainly used, and trace amounts of triamine and tetraamine may be used in combination as needed. These polyurethane elastomers may be used alone or in combination of two or more. In addition, the melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher that can maintain the heat resistance and durability, and the use of 160 ° C. or higher is more preferable because the heat resistance is improved. In addition, since the reticulated body of the present invention contains a phosphorus-based compound for imparting flame retardancy, its heat stability is slightly inferior to that containing no flame retardant. It is particularly preferable to improve the properties and durability. The antioxidant is preferably a hindered antioxidant, which includes a hindered phenol-based and a hindered amine-based antioxidant, and a nitrogen-free hindered phenol-based antioxidant of 1% to 5%. It is particularly preferable to suppress the thermal decomposition by adding it because the generation of a toxic gas having a small lethality during combustion can be suppressed. The content of the soft segment of the thermoplastic elastic resin constituting the component having the function of absorbing vibration and stress, which is the object of the present invention, is preferably 15% by weight or more, more preferably 30% by weight or more. Is preferably 80% by weight or less, more preferably 70% by weight or less. That is, the content of the soft segment of the component having the function of absorbing vibration and stress of the elastic network of the present invention is preferably from 15% by weight to 80% by weight, and more preferably from 30% by weight to 70% by weight. .
[0010]
The thermoplastic elastic resin used in the mesh body and other parts used in the seat of the present invention preferably has flame retardancy, and in particular, a phosphorus-containing composition is more preferable than a halogen-based composition. The flame retardant reticulated body has poor flame retardancy when the phosphorus content (Bppm) in the thermoplastic elastic resin does not satisfy 60 A + 200 or more with respect to the soft segment content (A weight%), and when it exceeds 100,000 ppm. Since the plastic deformation due to the plasticizing effect is large and the heat resistance of the thermoplastic elastic resin is inferior, it is preferable to satisfy the relationship of 60A + 200 ≦ B ≦ 100,000. The more preferable phosphorus content (Bppm) is 30A + 1800 ≦ B ≦ 100,000 based on the soft segment content (A wt%), and the more preferable phosphorus content (Bppm) is based on the soft segment content (A wt%). 16A + 2600 ≦ B ≦ 50,000. There is a method of imparting a high level of flame retardancy by adding a large amount of halides and inorganic substances, but a large amount of toxic halogen gas with a small lethal amount is generated at the time of combustion, and the problem of poisoning during a fire is reduced. There is a problem that the incinerator is greatly damaged during incineration. In the present invention, the content of the halide is preferably at least 1% by weight or less, more preferably the content of the halide is 0.5% by weight or less, and most preferably no halide is contained. As a preferred phosphorus-based flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic elastic resin, it is described in JP-A-51-82392 as a flame retardant in a hard segment portion during resin polymerization. Carboxylic acid such as 10 [2.3-di (2-hydroxyethoxy) -carbonylpropyl] 9.10-dihydro-9.oxa / 10-phosphaphenylene-10-oxylo is part of the acid component of the hard segment. Or a method in which a phosphorus-based compound such as tris (2,4-di-t-butylphenyl) phosphite is added to the thermoplastic elastic resin in a later step. Flammability can be imparted. In addition, examples of the flame retardant capable of imparting flame retardancy include various phosphates, phosphites, phosphonates (the above-mentioned phosphates containing a halogen element as necessary), or polymers derived from these phosphorus compounds. Can be illustrated. In the present invention, various modifiers, additives, coloring agents and the like can be added to the thermoplastic elastic resin as required. The reticulated body of the present invention preferably contains phosphorus in order to impart flame retardancy. This is because, as described above, from the viewpoint of safety, cyan gas, halogen gas and the like generated at the time of fire are used. The aim is to minimize toxic gases with low lethality. For this reason, the toxicity index of the combustion gas of the preferred flame-retardant network in the present invention is preferably 6 or less, more preferably 5.5 or less. When polyester fibers are used for the side layer and the wadding layer, the polyester fibers are preferably made of a polyester-based thermoplastic elastic resin so that they can be recycled without separation.
[0011]
The seat of the present invention is a seat comprising a back portion and a seat portion formed by a side portion, a cushion layer, and a deep-drawn back portion as main portions.
It is preferable that the filaments of the thermoplastic elastic resin constituting the net in the present invention have an endothermic peak below the melting point in a melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have remarkably improved heat resistance and sag resistance compared to those having no endothermic peak. For example, preferred polyester-based thermoplastic resins of the present invention include those containing 90 mol% or more of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment, more preferably terephthalic acid or the like. The content of naphthalene 2.6 dicarboxylic acid is 95 mol% or more, particularly preferably 100 mol%, and after transesterification of the glycol component, polymerization is carried out to a required degree of polymerization, and then as polyalkylenediol, preferably When polytetramethylene glycol having an average molecular weight of 500 to 5,000, particularly preferably 1,000 to 3,000 is copolymerized in an amount of 15 to 70% by weight, more preferably 30 to 60% by weight, Terephthalic acid or naphthalene 2,6-dicarboxylic acid having rigidity in the acid component of the hard segment If the content is large, the crystallinity of the hard segment is improved, plastic deformation is difficult, and heat resistance and set resistance are improved. However, after fusion bonding by heat, annealing is performed at a temperature at least lower than the melting point by at least 10 ° C. Treating improves heat resistance and sag resistance. Annealing after imparting compressive strain further improves heat resistance and sag resistance. An endothermic peak is more clearly exhibited at a temperature from room temperature to a melting point in the melting curve of the filaments of the network structure treated by the differential scanning calorimeter. When no annealing is performed, an endothermic peak does not appear in the melting curve from room temperature to the melting point. By analogy with this, it is considered that the annealing causes the hard segments to be rearranged, pseudo-crystallization-like crosslinking points to be formed, and the heat resistance to sag to be improved. (This treatment is defined as pseudo-crystallization treatment.) This pseudo-crystallization treatment effect is also effective for polyamide-based elastic resins and polyurethane-based elastic resins.
[0012]
Examples of the thermoplastic inelastic resin constituting the side lands and the resin molded body used for the seat of the present invention include polyester, polyamide, and polyolefin. In the present invention, it is preferable to use one having a glass transition temperature of at least 40 ° C. For example, for polyester, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), poly Examples thereof include butylene terephthalate (PBT), polybutylene naphthalate (PBN), polyarylate and the like, and copolyesters thereof. Examples of the polyamide include polycaprolactam (NY6), polyhexamethylene adipamide (NY66), and polyhexamethylene sebacamide (NY6-10). Examples of the polyolefin include polypropylene (PP) and polybutene-1 (PB-1). As the thermoplastic inelastic resin used in the present invention, polyester is often used on the side of the cushioning material. Therefore, as a cushioning material that can be recycled without being separated when discarded, PET and PEN having good heat resistance are also used. , PBN, PCHDT and the like are particularly preferred. When used in a resin molded product, a component for improving impact resistance in a range where required strength is maintained, for example, a thermoplastic elastic resin, PBT having a low glass transition temperature, polypropylene terephthalate (PPT), or polyhexene. It is preferable to add less than 5% of xylene terephthalate or the like. A flame-retardant network according to a preferred embodiment of the present invention has a phosphorus content in a thermoplastic inelastic resin of less than 1000 ppm, and has insufficient flame retardancy. Since the deformation becomes large and the heat resistance of the thermoplastic inelastic resin is inferior, the content is preferably 1000 ppm or more and 20000 ppm or less. A more preferred phosphorus content is 2,000 ppm to 10,000 ppm, most preferably 3,000 ppm to 8,000 ppm. There is a method of imparting a high level of flame retardancy by adding a large amount of halides and inorganic substances, but a large amount of toxic halogen gas with a small lethal amount is generated at the time of combustion, and the problem of poisoning during a fire is reduced. In addition, at the time of incineration, since the damage to the incinerator becomes large, it is preferable that the incinerator is not contained. In particular, vinyl chloride has a self-extinguishing property, but generates a large amount of toxic gas when burned, and is not preferred for use in the present invention. In the present invention, the content of the halide is at least 1% by weight or less, preferably the content of the halide is 0.5% by weight or less, and more preferably, it contains no halide. As the phosphorus-based flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic inelastic resin, at the time of resin polymerization, as a flame retardant, for example, 10 [2.3 ·] described in JP-A-51-82392 and the like can be used. Di (2-hydroxyethoxy) -carbonylpropyl] polyester-based thermoplastic inelastic resin obtained by copolymerizing a carboxylic acid such as 9,10-dihydro-9, oxa-10-phosphaphenene-10-oxylo as a part of an acid component Or in a post-process of injection molding a thermoplastic inelastic resin, for example, by adding a phosphorus compound such as tris (2,4-di-t-butylphenyl) phosphite to impart flame retardancy. be able to. In addition, examples of the flame retardant capable of imparting flame retardancy include various phosphates, phosphites, phosphonates (the above-mentioned phosphates containing a halogen element as necessary), or polymers derived from these phosphorus compounds. Can be illustrated. In the present invention, various modifiers, additives, coloring agents, and the like can be added to the thermoplastic inelastic resin as needed. The cushion body constituting the seat of the present invention contains phosphorus in order to impart flame retardancy. This is because, as described above, from the viewpoint of safety, cyan gas and halogen gas generated at the time of fire. And the like, in order to minimize toxic gas with a small lethal amount. Therefore, the toxicity index of the combustion gas of the cushion constituting the seat of the present invention is preferably 6 or less, more preferably 5.5 or less. In addition, by using a polyester-based thermoplastic inelastic resin for the side layer and the wadding layer, it is possible to recycle without separation.
[0013]
According to the present invention, the seat back or the deeply drawn portion on the back is made of an injection-molded resin molded product having an opening ratio of 10% or more, and the cushion layer winds a continuous filament having a fineness of 100,000 denier or less. An apparent density of 0.01 g / cm made of a thermoplastic elastic resin which is brought into contact with each other to form a three-dimensional three-dimensional structure in which most of the contact portion is fused; ³ From 0.2g / cm ³ (A cross-sectional view of the seat in FIG. 1, FIG. 2 (A)) in which the resin molded body and the net are integrally joined by an adhesive or self-adhesion, Fig. 2 shows a cross section between AA 'of the seat part and Fig. 2 (B) shows a cross section between BB' of the back part as an example of the present invention). In the seat of the present invention, the deep drawn portion on the back surface or the back surface of the seat is formed of a resin molded product having an opening ratio of 10% or more (FIG. 3 shows a resin molded product for a seat portion, and FIG. 4 shows a resin molded product for a back portion). Is shown as an example of the invention.), A resin molded body integrally joined with a local stress received from a cushion layer made of a mesh body having excellent elasticity and recoverability made of a thermoplastic elastic resin is formed on the entire surface. It is necessary to have a reinforcing function to be received at the same time and to also have a function of a convex core material such as a side portion. When the net and the resin molded body are not joined and integrated, it is not preferable because if the net undergoes a large deformation locally, the net structure may be broken. The shape of the resin molded body is preferably one having a pressure-resistant structure, for example, having a reinforcing beam structure, or having a hollow structure. As a result, the number of metal frame members can be reduced, and the weight can be reduced. It is not preferable to use a cushion layer also for the deep drawn portion on the back or back of the seat, since a nonwoven fabric reinforcing layer and a metal reinforcing frame are required, which increases the weight of the seat. Thus, the resin molded body needs to have a heating fluid penetrated during molding processing to be described later, and has an opening ratio of 10% or more to maintain air permeability when the seat is used. If it is less than 10%, the rate of temperature rise during molding will be slow, causing local thermal deterioration and poor shape formation, which is not preferable. In addition, even if the mesh member has good air permeability, insufficient ventilation on the back surface is not preferable because it tends to be stuffy. For the purpose of preventing stuffiness, the side portion may not have an opening, but preferably has an opening on the entire surface. The porosity of the resin molded article of the present invention is preferably 20% to 70%, more preferably 30% to 50%. The cushion layer of the present invention is made of a thermoplastic elastic resin in which continuous filaments having a fineness of 100,000 denier or less are meandered and brought into contact with each other to form a three-dimensional three-dimensional structure in which most of the contact portions are fused. Apparent density is 0.01g / cm ³ From 0.2g / cm ³ Because it is composed of a mesh body, most vibrations are absorbed and attenuated by the vibration absorption function of the thermoplastic elastic resin, and even if a large deformation stress is applied locally, The surface is substantially flattened by thermoforming and most of the contact parts are fused, receiving deformation stress on the surface of the cushion layer, dispersing the deformation stress, and forming a three-dimensional line made of thermoplastic elastic resin. Since the structure is formed and fused and integrated with the resin molded body having a reinforcing function, the seat structure is retained, and the net structure easily deforms as a whole and the deformation stress is generated by energy conversion. When the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original shape, so that the sag resistance is excellent. A known net made of a filament made of only an inelastic resin does not have rubber elasticity, so that it undergoes plastic deformation due to compressive deformation and does not recover, resulting in poor durability. If the filaments of the mesh are not continuous, the adhesion point becomes the point of transmission of stress, so that significant stress concentration occurs at the adhesion point, causing structural destruction, and causing the structural failure. However, the heat resistance and durability are inferior as in the structures disclosed in JP-A-61-137732, WO91-19032 and the like. Hard cotton using a fiber made of an inelastic resin as a matrix is not preferable for use as a cushion layer because plastic deformation occurs and sag resistance is poor. If not fused, the shape cannot be maintained, and the structure does not deform integrally, so that fatigue phenomena due to stress concentration occur and the durability is deteriorated, and at the same time, the shape is deformed and the body shape cannot be maintained, which is not preferable. . A more preferable degree of fusion according to the present invention is a state where most of the portions where the filaments are in contact are fused, and most preferably a state where all the contact portions are fused. The function of the cushioning material is to make the basic cushioning layer a little thicker and a little harder to maintain body shape, and a layer that has a slightly higher density with a good vibration damping component to absorb vibration and block vibration The surface layer is a slightly softer layer with a slightly thinner fineness and a larger number of lines, giving a comfortable buttocks touch by moderate sinking and evenly distributing the pressure distribution of the buttocks with a cushion layer. By integrating the layer that absorbs the vibration that could not be absorbed and blocks the vibration of the resonance part of the human body, it is possible to integrally deform and absorb the stress and the vibration, thereby improving the sitting comfort. Thus, continuous filaments made of thermoplastic elastic resin having good vibration absorption and elastic recovery properties form a three-dimensional three-dimensional structure in which most of the contact portions are fused, are fused and integrated, and the surface is substantially flat. A cushion body in which a resin layer having a reinforcing function is integrally bonded to the rear side of the cushion layer and the cushion layer by an adhesive or self-adhesion, the surface layer receives deformation stress on the surface, improves dispersion of stress, It is supported by the resin molded body by reducing the stress applied linearly, the entire net structure is deformed while maintaining its shape, absorbs the deformation stress, and also improves the cushioning that supports the buttocks, recovers when the stress is released The vibration transmitted from the frame is also absorbed by the cushion layer made of thermoplastic elastic resin, which has good vibration absorption and elastic recovery properties, and cuts off the vibration of the resonance part of the human body to improve sitting comfort and durability. Can. The fineness of a filament made of a thermoplastic elastic resin having good vibration absorbing properties and elastic recovery properties that forms the net of the present invention is 100000 denier or less. The apparent density of the cushion layer of the seat is 0.2 g / cm ³ In the following cases, if the density exceeds 100,000 denier, the number of components is reduced, a density unevenness occurs, a partially inferior durable structure is formed, fatigue due to stress concentration increases, and durability deteriorates. The fineness of the filament made of the thermoplastic elastic resin of the present invention is 100 denier or more because the anti-compression property is too low if the fineness is too small and the stress absorption due to deformation is reduced. It is 50,000 denier or less which does not impair the denseness of the structure. More preferably, it is 500 to 10,000 denier. The average apparent density of the mesh forming the cushion layer of the present invention is 0.005 g / cm. ³ In this case, the repulsive force is lost, and the vibration absorbing ability and the deformation stress absorbing ability become insufficient, so that it may be difficult to exhibit the cushion function. ³ Above, the resilience is too high and the sitting comfort may be poor, so that the function as a cushion body is easily exhibited by utilizing the vibration absorbing ability and the deformation stress absorbing function. ³ 0.20 g / cm or more ³ Or less, preferably 0.03 g / cm ³ 0.08 g / cm or more ³ It is as follows. In the present invention, a method of forming a layered structure of different fineness, which has an optimal configuration in combination with the apparent density of linear shapes having different fineness, can also be selected as a preferred embodiment. The thickness of the reticulated body of the present invention is not particularly limited, but if the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are reduced. Therefore, the preferred thickness can exhibit a surface function for dispersing force and a vibration and deformation stress absorbing function. The thickness is 10 mm or more, more preferably 20 mm or more. In the case where an adhesive is used in the method of joining and integrating the resin molded body and the net-like body of the seat of the present invention, the adhesive is preferably a resin having good adhesiveness to both the net-like body and the resin molded body. In particular, those having thermal adhesiveness are preferred. As a particularly preferred embodiment, for example, when the reticulated body is a polyester-based thermoplastic elastic resin and the resin molded body is a polyester-based thermoplastic elastic resin or a polyester-based thermoplastic inelastic resin, at least the reticulated thermoplastic elastic resin is used. A polyester resin having a melting point lower than the melting point by 10 ° C. or more is preferable. Preferably, a material having a melting point lower by 20 ° C. to 50 ° C. than the melting point of the mesh body is good. In order to withstand deformation of the cushion layer, a thermoplastic elastic resin is particularly preferable. Although the form of the adhesive is not particularly limited, there is a method of applying a film, a nonwoven fabric, a powder or a solution, and the like, but a nonwoven fabric is particularly preferable because hot air is passed therethrough for thermal bonding. As the nonwoven fabric, a spunbonded nonwoven fabric made of a thermoplastic elastic resin, a melt blown nonwoven fabric, a short fiber nonwoven fabric, or the like can be used. In the case of self-adhesion, in order to impart a thermal bonding function to the filaments of the mesh, the mesh is formed by filaments having a high melting point component and a low melting point component in a sheet core structure or a side-by-side structure. When the filaments of the network have a composite structure, a preferable heat bonding function can be provided. For example, in the sheath core structure, a thermoplastic elastic resin having a large soft segment content, which is easy to convert the vibration and deformation stress of the sheath component into energy, is used as a heat bonding component, and a soft segment containing a core component having anti-compression property is included. A structure in which a small amount of thermoplastic elastic resin is used as a high melting point component to have a holding function in a net-like form, and a material having a melting point of the heat bonding component lower than the melting point of the high melting point resin by 10 ° C. or more is used. Can also be provided. It is also preferable to laminate the surface layer of the flame-retardant reinforcing mesh body of the present invention with a low melting point thermoplastic elastic resin having a large soft segment content, which can easily convert vibration and deformation stress into energy, as a heat bonding component. An adhesive function can be provided. The melting point of the heat bonding component that forms the filaments in the network is preferably 15 to 50 ° C. lower than the melting point of the high melting point component, and more preferably 20 to 40 ° C. lower than the melting point of the high melting point component. is there. The seat of the present invention, which has a cushion body having such a cushioning function and is fixed to the frame by covering the side ground, for example, having a cross section shown in FIG. 1, blocks vibration, and has heat resistance, durability, shape retention and cushioning properties. It is an excellent vehicle seat that is resistant to stuffiness. In addition, it is particularly preferable to use the flame retardant thing from the viewpoint of safety as the side land of the seat of the present invention.
[0014]
By arranging a wadding layer made of fiber-fill between the mesh of the seat of the present invention and the side ground, the touch of the seat is softened, which is preferable. It is particularly preferable for the wading layer to use heat-adhesive fibers made of thermoplastic elastic resin, since the heat-resistant durability and the cushioning property are improved. It is not preferable to use a fiber made of a thermoplastic inelastic resin as the heat bonding fiber, because the heat resistance is inferior. When the wading layer is used as a thermal bonding component between the side layer and the cushion layer, by using a fiber having a thermoplastic elastic resin having a melting point at least 10 ° C. lower than the melting point of the thermoplastic elastic resin of the mesh body as a thermal bonding component. This is a preferred embodiment because the network structure can be maintained and the network body and the side ground can be thermally bonded.
[0015]
In the present invention, the cross-sectional shape of the filaments of the mesh body is not particularly limited, but it is particularly preferable that a hollow cross-section or a modified cross-section can impart a preferable anti-compression property (repulsive force) and a touch. The anti-compression property can be adjusted by fineness and the modulus of the material used to make the fineness thinner.For soft materials, the hollowness and irregularity can be increased to adjust the gradient of the initial compressive stress, and the fineness can be made slightly thicker. A material with a high modulus reduces the hollowness and the degree of irregularity, and provides good seating comfort and compression resistance. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the degree of irregularity, when the same compression resistance is imparted, it is possible to further reduce the weight, and when used for a seat of an automobile or the like, energy saving can be achieved. it can. As another preferable method capable of imparting a preferable anti-compression property (repulsive force) and a touch, there is a method in which the filaments of the mesh body of the present invention have a composite structure. Examples of the composite structure include a core-score structure or a side-by-side structure, and a combination thereof. However, in order to obtain a three-dimensional three-dimensional structure in which vibration and deformation stress, which cannot convert energy even if the cushion layer undergoes large deformation, can be recovered by converting the energy into energy, 50% or more of the linear surface is made of a soft thermoplastic elastic resin. Occupied by a core-score structure or a side-by-side structure and a combination thereof. That is, in the core-score structure, the sheath component is a thermoplastic elastic resin having a large soft segment content that facilitates energy conversion of vibration and deformation stress, and the core component has a small soft segment content exhibiting anti-compression property. It is made of a plastic elastic resin and can give a comfortable touch to the buttocks by moderate sinking. In the side-by-side structure, the melt viscosity of a thermoplastic elastic resin with a large soft segment content that facilitates energy conversion of vibration and deformation stress is lower than the melt viscosity of a thermoplastic elastic resin with a small soft segment content and anti-compression properties. A structure in which the proportion of thermoplastic elastic resin with a large soft segment content occupying a linear surface is increased (figuratively a structure in which thermoplastic elastic resin is arranged on an eccentric sheet-core structure sheet) It is particularly preferable that the proportion of the thermoplastic elastic resin occupying a linear surface and having a large soft segment content is 80% or more, and most preferably the thermoplastic elastic resin having a large soft segment content occupying a linear surface. Is a scoring score, where the ratio of the is 100%. When the proportion of the linear surface of the thermoplastic elastic resin having a large soft segment content occupies a large proportion, the fluidity at the time of melting and fusing is high, so that there is an effect that the adhesion becomes strong, and the structure is integrally deformed. In this case, the fatigue resistance against stress concentration at the bonding point is improved, and the heat resistance and durability are further improved.
[0016]
Next, the production method of the present invention will be described. Since the mesh in the present invention is not known at the time of the present invention, its production method will be described in detail. Distributing the thermoplastic elastic resin to each nozzle orifice from a multi-row nozzle having a plurality of orifices, and discharging downward from the nozzle at a melting temperature higher than the melting point of the thermoplastic resin by 20 ° C or more and less than 80 ° C, While being brought into contact with each other in a molten state and being fused to form a three-dimensional structure, it is sandwiched by a take-off device and cooled in a cooling bath to obtain a continuous net-like body. In the present invention, as described above, flame retardancy is not a necessary condition, but in order to impart flame retardancy as necessary, a method of adding a phosphorus compound at the time of polymerization and copolymerizing, and a method of mixing and kneading by adding after the polymerization. Can be included. Mixing and kneading can be carried out using a twin-screw kneading extruder or a single-screw extruder having a kneading function such as dalmage and pins, and can be selected to be carried out before melt extrusion or to be carried out by a method such as quantitative supply during melt extrusion. . If the flame retardant can be supplied at a constant rate, kneading during melt extrusion is the cheapest method. In such a method, preferably, a phosphorus content satisfying the relationship of 60A + 200 ≦ B ≦ 100,000 is added to the thermoplastic elastic resin so that the amount of the soft segment (A weight%) and the phosphorus content (Bppm) are added. To form a mesh. The molten phosphorus-containing thermoplastic elastic resin is supplied to a multi-row nozzle having a plurality of orifices, and is discharged below the orifices. In the case of compounding the filaments, the thermoplastic elastic resin separately melt-kneaded from a number of extruders is separately mixed and flowed so as to be compounded immediately before the orifice of the multi-row nozzle, and is discharged downward. In the core score, the core component is supplied from the center, and the sheath component is joined and discharged from around the core component. In side-by-side, the components are combined and discharged from left and right or front and rear. The melting temperature at this time is a temperature higher by 10 ° C. to 80 ° C. than the melting point of the thermoplastic elastic resin. (When combined, the same melting temperature of 10 ° C. or higher than the melting point of the high melting point component and 80 ° C. or lower than the melting point of the low melting point component is preferable.) Then, thermal decomposition is remarkable, and the rubber elasticity of the thermoplastic elastic resin is deteriorated. On the other hand, if the temperature is not higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and a normal filament cannot be formed. The temperature is lowered, and the filaments may not fuse with each other, resulting in a network having insufficient adhesion, which is not preferable. Preferred melting temperatures are 25 to 60 ° C above the melting point, more preferably 30 to 40 ° C above the melting point. Although the shape of the orifice is not particularly limited, a hollow cross section (for example, a shape having a triangular hollow, a round hollow, a hollow with a projection, or the like) and a deformed cross section (for example, a triangular, Y-shaped, star-shaped, etc. In addition to the above-described effects, the three-dimensional structure formed by the melted discharge filaments is less likely to relax the flow, and conversely, the flow time at the contact point is maintained longer to strengthen the bonding point. It is particularly preferable because it can be made. In the case of heating for bonding as described in JP-A-1-2075, the three-dimensional structure is easily relaxed, resulting in a planar structure, which makes it difficult to form a three-dimensional structure. As the effect of improving the properties of the net-like body, the apparent bulk can be increased and the weight can be reduced, and the compression resistance and the resilience can be improved. In the case of a hollow cross section, if the hollow ratio exceeds 80%, the cross section is easily crushed. Therefore, it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less, at which the effect of weight reduction can be exhibited. The pitch between the holes of the orifices must be such that the loop formed by the line can sufficiently contact. The pitch between holes is shortened for a dense structure, and the pitch between holes is increased for a dense structure. The pitch between the holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different densities and different finenesses can be obtained as desired. A different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is changed, or a method in which both the pitch between rows and between holes are also changed. In addition, if the pressure loss difference at the time of discharge is given by changing the cross-sectional area of the orifice, a principle is used in which the discharge amount of molten thermoplastic elastic resin extruded from the same nozzle at a constant pressure decreases as the orifice with a large pressure loss decreases. Using a nozzle having at least a plurality of rows having different cross-sectional areas of orifices in a section in the longitudinal direction, it is possible to manufacture a net-like structure made of different fineness filaments. Next, the nozzles are discharged downward from the nozzle, and are brought into contact with each other in a molten state while forming a loop to be fused to form a three-dimensional structure. After bending and deforming the winding wire in the molten state on the surface of the mesh body by 45 ° or more to flatten the surface and simultaneously bonding the points of contact with the unbent discharge wire to form a structure, Then, the mixture is quenched with a cooling medium (usually, water at room temperature is preferably used because the cooling rate can be increased and the cost is reduced) to obtain a three-dimensional three-dimensional network structure of the present invention. It is preferable that the distance between the nozzle surface and the take-up point is at least 40 cm or less to prevent the discharge filaments from cooling and preventing the contact portion from being fused. When the discharge amount of the discharge line is as large as 5 g / minute or more, it is preferably 10 cm to 40 cm. When the discharge amount of the discharge line is less than 5 g / minute hole, it is preferably 5 cm to 20 cm. The thickness of the net-like body is determined by the opening width of the take-off net sandwiching both surfaces of the three-dimensional three-dimensional structure in the molten state (interval between the take-up nets). In the present invention, the opening width of the take-up net is set to 5 mm or more for the above-described reason. Then, drying with water is performed. However, if a surfactant or the like is added to the cooling medium, draining or drying becomes difficult, and the thermoplastic elastic resin may swell, which is not preferable. The desired loop diameter and wire diameter can be determined by the distance between the nozzle surface and a take-off conveyor set on a cooling medium for solidifying the resin, the melt viscosity of the resin, the hole diameter of the orifice, and the discharge amount. A pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwich and hold the discharge line in the molten state to fuse the parts that have come into contact with each other while continuously drawing it into the cooling medium and solidifying it. When the body is formed, by adjusting the interval between the conveyors, the thickness can be adjusted while the fused net is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or cooling may occur until the fusion points are sufficiently formed, and the fusion of the contact portions may be insufficient. On the other hand, if the speed is too low, the melt stays too much and the density becomes high. Therefore, it is necessary to set a conveyor speed suitable for a desired apparent density. The net thus obtained is then punched into a shape corresponding to the cushion form of the seat to obtain a cut net having a predetermined shape. When the mesh is used for the cushion layer, it is necessary to select the resin, fineness, loop diameter, and bulk density to be used depending on the purpose of use and the site of use. For example, in order to provide a soft touch, a moderate sunk and a firm bulge, it is preferable to use a low density, fine fineness, and a small loop diameter. Medium-density, large fineness, and slightly larger loop diameter layer to reduce vibration frequency, moderately change hardness and hysteresis during compression linearly to improve body shape retention and maintain durability. It is preferable to form a structure in which layers of low density, fine fineness and small loop diameter are laminated and integrated. In addition to the resin manufacturing process, the molded product is processed from the manufacturing process to the extent that the performance is not degraded, and at any stage of seating, flame retardancy, insect and antibacterial, heat resistance, water and oil repellency, coloring, fragrance, etc. The function can be imparted by processing such as adding a drug.
On the other hand, the resin molded body, using a generally known injection molding machine, a thermoplastic elastic resin, or a thermoplastic inelastic resin, or a mixture thereof, and a necessary modifier such as a flame retardant, for example, twin-screw extrusion. The molten resin melt-mixed using a machine is extruded into a mold having, for example, the shapes shown in FIGS. 3 and 4, and cooled to obtain an injection molded body. The temperature of the mold at the time of extruding the resin is set at a temperature lower than the melting point of the resin by 30 ° C. from the melting point of the resin. This is desirable because the adhesion to the mesh at the time becomes strong.
[0017]
Next, the seat of the present invention arranges a mesh member serving as a cushion layer cut into a predetermined shape in a female mold, and arranges a resin molded body formed in a deep drawing shape serving as a back surface or a back surface thereon, or An adhesive layer having a melting point lower by at least 10 ° C. than the melting point of the mesh body is disposed between the mesh body and the resin body, and the cushion layer is compressed from above with a male mold, and the resin layer is also protruded from the inside of the recess through the resin body. After compressing the part, heating it with a heating medium at a temperature 5 ° C. higher than the melting point of the reticulated body to 50 ° C. lower than the melting point and integrating it by thermoforming, once cooling or continuously, the glass of the reticulated body A cushion molding obtained by annealing at a temperature higher than the transition temperature by at least 10 ° C. and at a temperature lower by at least 20 ° C. than the melting point is fixed to a seat frame by attaching a side ground. Hereinafter, the molding method will be described with reference to the drawings. As shown in FIG. 5 (A), the

nets

2 and 2 ′ cut into a predetermined shape are placed on a female mold 7 having a vent hole 8, and then opened as shown in FIG. 5 (B). The resin molded body 3 having the hole 4 is put on the resin molded body 3 from above, and then the net 2 is wound up to the back side of the resin molded body 3 and hooked on the hook 9 for stopping the net 2 on the back side of the resin molded body 3. Stop body 2. Next, as shown in FIG. 5 (C), it is compressed by a male mold 10 having a vent 8. By compressing from above with the male mold 10, the convex portion 3 ′ of the resin molded body 3 transmits a compressive force from the inside of the mesh body 2 to the outside of the mesh body 2, and is compressed into a shape that closely follows the shape of the female mold 7. Is done. Next, the whole is heated by passing a heating fluid from the direction of the arrow, and thermoformed. At this time, the temperature of the heating fluid is a temperature at which a part of the reticulated body is plastically relaxed and deformed into the shape of the seat, and the resin molded body is not plastically deformed. For example, (Example 1) In the case where the reticulated body has a single composition, the reticulated body is heated at a temperature higher by 5 ° C. than the melting point of the reticulated body to melt the surface of the filament of the reticulated body and heat-bond to the resin molded body. If the melting point of the net is higher than the melting point by 10 ° C. or more, it is not preferable because the shape of the net is lost and the cushion function is reduced. In the case where the reticulated body is formed of a linear core having a core-score structure, for example, (Example 2) thermoforming at a temperature 5 ° C. or higher than the melting point of the sheet component and 5 ° C. higher than the melting point of the core component of the reticulated body. This is a preferable case in which the mesh structure can be maintained to form a desired seat shape and the thermal bonding with the resin molded body can be strengthened. A temperature at which the core component does not undergo plastic deformation, for example, a temperature lower than the melting point by 60 ° C. or more, is not preferable because a desired seat shape cannot be formed. For example, when the net-like body has a single composition and an adhesive is used, (Example 3) the adhesive is applied to the surface of the resin molded body 3 before being set in FIG. 5B, or (Example 4). As shown in FIG. 6, even when the heat-bonded nonwoven fabric 12 is laminated and thermoformed, for example, a resin made of a thermoplastic elastic resin having a melting point of an adhesive of 160 ° C. or a melt-blown nonwoven fabric 12, and the

nets

2 and 2 ′ Is 220 ° C., the heating temperature is preferably 170 ° C. or more and 225 ° C. or less. (Example 5) FIG. 6 shows a case where a fiber-fill is used for the wadding layer 11 according to an example of the embodiment of the present invention. For example, a fiber-fill web using a polyester-based thermoplastic elastic resin as a heat bonding component is used. When the melting point of the heat bonding component is 185 ° C., the base material of the fiber-fill web is PET having a melting point of 265 ° C., the melt-blown nonwoven fabric 12 of the adhesive is 160 ° C., and the melting points of the

meshes

2 and 2 ′ are 220 ° C. It is preferable to perform thermoforming at a temperature 10 ° C. higher than 185 ° C., which is higher in the melting point of the heat bonding component, and 5 ° C. higher than the melting point of the net, that is, 195 ° C. to 225 ° C. If the heating time is not shorter than 15 minutes, the thermal decomposition of the low melting point component is promoted and the adhesive function is lowered, and the productivity is undesirably lowered. Preferably, the temperature is raised to the heating temperature within 10 minutes, more preferably within 5 minutes, the heating temperature is maintained for about 1 to 5 minutes, the molding is performed, and then cooling is performed. As a preferred method of the present invention, the temperature is at least 10 ° C. higher than the glass transition temperature of the thermoplastic elastic resin, and at least 10 ° C. higher than the melting point in any step leading to commercialization after continuous or once cooling and integral molding. It is a more preferable production method to perform a pseudo-crystallization treatment by annealing at the following temperature. The pseudo-crystallization temperature is at least 10 ° C. lower than the melting point (Tm) and higher than the α-dispersion rising temperature (Tαcr) of Tan δ, which is the glass transition temperature of the hard segment. This treatment has an endothermic peak below the melting point, and significantly improves heat resistance and sag resistance as compared with those without pseudo-crystallization treatment (without endothermic peak). The preferred pseudo crystallization treatment temperature of the present invention is (Tαcr + 10 ° C.) to (Tm−20 ° C.). In the case of continuous annealing, for example, in Example 1, the glass is cooled to a temperature higher than the glass transition temperature + 10 ° C. and lower than the melting point by 20 ° C. or more. Remove the cushion from the mold. In Example 1, when the melting point of the network is 220 ° C. and the glass transition temperature is 50 ° C., the heating state is maintained at 60 ° C. or more, preferably 100 ° C. to less than 200 ° C., and preferably 150 ° C. for 5 to 10 minutes. Is good. In Example 2, when the core component has a glass transition temperature of 185 ° C. and the core component has a glass transition temperature of 50 ° C., the temperature is 60 ° C. from a temperature 20 ° C. or more lower than the melting point of the sheath component. As described above, annealing is preferably performed at a temperature of 100 ° C. or more and 165 ° C. or less, preferably 130 ° C. or less. In Examples 3, 4 and 5, it is preferable to perform annealing at 60 ° C or higher, preferably 100 ° C or higher and 140 ° C or lower, preferably 130 ° C or lower. The same effect is exhibited by annealing once after cooling and discontinuously. Thus, a cushion body having further improved heat resistance and sag resistance even when pseudo-crystallized by simple heat treatment is obtained. However, it is more preferable to separately apply a compression deformation of 10% or more and to perform annealing, since heat resistance and set resistance are remarkably improved. The cushion body thus obtained is covered with the side cloth 1, preferably with a flame-resistant side cloth, for example, a polyester moquette made of a flame-retardant polyester fiber heim manufactured by Toyobo Co., Ltd., and attached to the cushion body. At the same time, the side ground is stopped on the back side of the cushion body, and the side ground 1 is attached to the cushion surface, and from the concave portion of the cushion body, for example, Japanese Utility Model Laid-Open No. 56-101071, Japanese Utility Model Laid-Open No. 60-109499, The resin molded body 3 is penetrated by the pull-in button or the like disclosed in the above, and the side ground is suspended, or a known suspension method, for example, a hanging jig is set in advance on the convex portion of the female mold 7 and then thermoformed. It is also possible to adopt a method in which the side ground 1 is fixed along the cushion body by fixing the resin body 3 or the reinforcing frame 6 from the cushion body recess. Then, the seat of the present invention is obtained by fixing to the set frame of the seat.
[0018]
The seat of the present invention uses a mesh made of thermoplastic elastic resin having good recoverability and vibration absorption for the cushion layer, and a porous resin molded body constitutes a deep drawing part in the conventional cushion body, It has good ventilation, has the effect of core material of the convex part, and improves the shape retention of the cushion body, so it is ideal for seats for automobiles and railway vehicles, vibration insulation, heat resistance and durability. It is a highly safe seat that has excellent stiffness and cushioning properties, is resistant to stuffiness, has flame retardancy, and has a low toxicity index of combustion gas. Further, in the cushion body using a conventionally known fiber-fill, it is difficult to perform deep drawing, and the forming is complicated. However, in the method of the present invention, the forming can be performed in one step by omitting the deep drawing. In addition, a useful seat can be provided at low cost by reducing the cost of molding processing. Of course, it is also useful for seats for ships, offices, furniture, etc. in addition to vehicles.
[0019]
【Example】
Hereinafter, the present invention will be described in detail with reference to Examples.
[0020]
The evaluation in the examples was performed by the following method.
1. Endothermic peak below melting point (Tm) and melting point
An endothermic peak (melting peak) temperature was determined from an endothermic curve measured at a heating rate of 20 ° C./min using a Shimadzu TA50 / DSC50 differential thermal analyzer.
2. Tαcr
The polymer was heated to a melting point of + 10 ° C. to form a film having a thickness of about 300 μm, and Tanδ (imaginary elastic modulus M ″) was measured at 110 Hz at a heating rate of 1 ° C./min using a Vibron DDVII model manufactured by Orientec. The rise temperature of α-dispersion corresponding to the transition point temperature from the rubber elastic region to the melting region of the ratio M ″ / M ′) of the elastic modulus to the real part M ′).
3. Apparent density
The sample is cut into a size of 15 cm × 15 cm, the height of four places is measured, the volume is determined, and the weight of the sample is indicated by a value obtained by reducing the volume. (Average value of n = 4)
4. Filament fineness
Each linear portion is cut out of the sample from 10 places, embedded in an acrylic resin, the cross section is cut out, and a slice is prepared to obtain a cross-sectional photograph. The cross-sectional area (Si) of each part is determined from a cross-sectional photograph of each part. Further, the section obtained in the same manner is prepared by dissolving the acrylic resin in acetone, degassing in vacuo, and measuring the specific gravity (SGi) measured at 40 ° C. using a density gradient tube. Next, the linear weight of 9000 m is obtained from the following equation. (Unit cgs)
Fineness = [(1 / n) Σ Si x SGi] x 900000
5. Fusion
Whether or not the sample is fused is determined by visually judging whether or not the bonded fibers are detached by pulling the bonded fibers by hand.
6. Heat resistance (70 ° C residual strain)
The sample was cut into a size of 15 cm × 15 cm, compressed by 50%, allowed to stand in a dry heat at 70 ° C. for 22 hours, cooled to remove the compression strain, and the thickness (b) after one day of standing was determined. ) Is calculated from the following equation, that is, (a + b) / a × 100. Unit% (average value of n = 3)
7. Cyclic compression strain
The sample was cut into a size of 15 cm × 15 cm, and compression recovery was repeated at a cycle of 1 Hz to a thickness of 50% in a 25 ° C., 65% RH chamber using a Shimadzu SERVO pulsar, and the sample after 20,000 times was repeated. The thickness (b) after being left for one day is calculated, and the thickness (a) before the treatment is calculated from the following formula, that is, (a + b) / a × 100. Unit% (average value of n = 3)
8. Combustion gas toxicity index
It shows the integrated value of the value obtained by dividing each combustion gas amount (mg) measured by the method of JIS-K-7217 by lethal dose (mg / 10 liter) when inhaled for 10 minutes.
9. Comfort
The paneler was seated on a seat prepared by the method of the present invention or a seat prepared by a comparative method in a room at 30 ° C. and 75% RH, and the following evaluation was performed. (N = 5)
(1) Feeling of flooring: The degree of "dancing" when sitting and the feeling of hitting the floor were sensually evaluated qualitatively. Not felt; ◎, almost felt; ○, slightly felt; △, felt; ×
(2) Feeling of stuffiness: After sitting for 2 hours, the sensation of sensational qualitative evaluation of the feeling of stuffiness in the buttocks and the part in contact with the seat inside the crotch was evaluated. Hardly felt: ◎, slight stuffiness; ○, slightly stuffy; △, marked stuffiness; ×
(3) How long you can sit in the seat within 8 hours: within 1 hour; × within 2 hours; △ within 4 hours; ○, over 4 hours;
(4) A qualitative evaluation was made on the degree of tiredness of the waist when sitting in a seat for 4 hours. None; ◎, hardly tired; ○, slightly tired; △, very tired; ×
(5) Comprehensive evaluation: Evaluation of (1) to (4): 12 points or more, with 4 points for ◎, 3 points for ○, 2 points for △, 1 point for ×, not including 含ま; very good (◎), 12 points or more containing Δ; good (○), 10 points or more, not containing ×; slightly poor (△), something containing ×, poor (×).
10. durability
Using a device that can be repeatedly compressed with a compression force of 60 kg using a flat plate with a diameter of 10 cm on the center and sides of the seat (seat and back) that has been created, it is repeatedly compressed 100 times at a cycle of 0.5 Hz. Was determined based on the following criteria. ◎: No settling. ：: Mild slight. Δ: There is a slight dent, and the sagging of the side ground comes out and the dent is recognized. ×: The dent is large and noticeable. (Average value of n = 3)
[0021]
Example 1
As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DMN) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, and transesterified by a conventional method. Polytetramethylene glycol (PTMG) was added, and polycondensation was carried out while raising and lowering the temperature to produce a polyetherester block copolymer elastomer. Then, 2% of an antioxidant was added, mixed, kneaded, and pelletized. The formulation of the thermoplastic elastic resin raw material obtained by vacuum drying at 48 ° C. for 48 hours is shown in Table 1.
[0022]
[Table 1]

[0023]
An orifice shape with a staggered arrangement of 10 mm in the width direction and 5 mm in the length direction between holes on the nozzle effective surface of 50 cm in width and 5 cm in length has an outer diameter of 2 mm and an inner diameter of 1.6 mm. The obtained A-1 and A-2 were separately supplied to the cross-sectioned nozzles by two extruders having a kneading function, and the existing chemical substance number (3) -3735 was used as a flame retardant. Is added so as to have a phosphorus content of 10000 ppm, and the mixture is melt-kneaded. A-1 and A-2 are immediately before the orifice so that A-1 is a sheath component and A-2 is a core component. (Discharge / core: 50/50 weight ratio) Distributed to the back of the orifice, discharged at 245 ° C. below the nozzle at a discharge rate of 2.0 g / min per single hole, and provided cooling water 10 cm below the nozzle surface. , 60cm wide stainless steel endless A pair of take-off conveyors are arranged in parallel at 5 cm intervals so as to partially emerge above the surface of the water, and are sandwiched between both sides at a speed of 1 m / min into 25 ° C. cooling water, solidified, and then drained. Table 2 shows the characteristics of the net 2 obtained by cutting into a predetermined size. The reticulated body used in Example 1 had a triangular diaper-shaped hollow cross section having a sea core structure, a hollow ratio of 40%, a fineness of 9000 denier, and a phosphorus content of 10,000 ppm (60A + 200 = 2780 ppm). And the average apparent density is 0.045 g / cm ³ Met. This reticulated body has a cushioning function with excellent heat resistance and durability at room temperature due to a reticulated structure that makes use of the characteristics of soft elastic resin, a highly safe cushioning layer with low flame index and low combustion gas toxicity index. Met.
[0024]
[Table 2]

[0025]
95 parts of polyethylene terephthalate and 5 parts of A-1 are mixed and dried, supplied to an extruder, melt-kneaded at 275 ° C., and a back and a seat having an opening of φ4 mm on the entire surface. The resin molded body 3 obtained by injecting the kneaded and melted thermoplastic resin at a residual heat temperature of 260 ° C. into the resin mold for cooling, and taking out after cooling, had a porosity of 36%.
[0026]
PBT having a relative viscosity of 1.2 and PET having an intrinsic viscosity of 0.58 are distributed and discharged side by side at 285 ° C. immediately before the hollow C-type orifice, and an undrawn yarn is spun by a conventional method, and then drawn. After applying mechanical crimping to the resulting fiber, a three-dimensional crimp is developed at 165 ° C. in dry heat and cut into 51 mm, and the fineness is 13 denier, the crimping degree is 35%, and the number of crimps is 23 peaks / A preform of fiber-fill web having a three-dimensional crimp with a round cross section having an inch and a hollow ratio of 28% was obtained. A-1 is used as a sheath component, and A-2 is used as a core component. The mixture is discharged at 260 ° C., and the fiber produced at a spinning speed of 3,500 m / min is combined into 20,000 denier and crimper-formed. After applying the mechanical crimp, it was cut to 51 mm to obtain a heat-bonded fiber having a fineness of 5 denier, a shrinkage of 8% at 160 ° C. in dry heat, and a solid round cross-section of the sheet core. . 60 parts of the obtained base material and 40 parts of the heat bonding fiber are mixed by a conventional method to prepare a card web, laminated, needle punched and cut to a predetermined size, and a 10 mm thick fiber fill web. 11 was created.
[0027]
A-1 is melted at 240 ° C., and is weighed with a heated air at 280 ° C. by a conventional method at 30 g / m ² Thus, a melt blown nonwoven fabric 12 in which fibers having a fineness of 0.05 denier were fused together was obtained.
[0028]
As shown in FIG. 6 (A), the fiber-fill web 11 and the reticulated bodies 2 and 2 'are laminated on a female mold, and the melt-blown non-woven fabric 12 is laminated between the layers. As shown in FIG. 6, the resin molded body 3 is placed and pressed down, and the fiber-fill web 11, the reticulated body 2, and the melt-blown non-woven fabric 12 are folded back to the back side of the resin molded body 3, hooked on the hook 9, and then stopped. As shown in (C), the mold is pressed and compressed by a male mold 10, forcibly penetrated with 200 ° C. heated air, heated for 5 minutes, heated at 2 minutes, and heated at 130 ° C. And then subjected to a cooling unring for 10 minutes, cooled and thermoformed, the average apparent density of the cushion layer of the seat portion being 0.058 g / cm. ³ The average apparent density of the back cushion layer is 0.055 g / cm. ³ A cushion body was obtained. Then, dimethyl terephthalic acid and 10 [2.3-di (2-hydroxyethoxy) -carbonylpropyl] 9.10-dihydro-9-oxa-10-phospha-phenylene-10-oxylo in an amount to give a phosphorous content of 5000 ppm. And a 2-denier stage in which copolymerized PET obtained by charging DEG with a small amount of a catalyst as a glycol component, subjecting it to transesterification, and subjecting it to polycondensation while increasing the temperature and pressure under reduced pressure is subjected to a conventional method. Using a pull, a basis weight of 450 g / m made of polyester fiber obtained by a conventional method ² , Air permeability 90cc / cm ² -Cover the surface of the cushion body with the side cloth 1 of the second moquette, pull it to the back side, stop it on the resin molded body while stretching the side ground, and mold the resin between the side and the center with the return button with the return The body 3 was penetrated, the side ground was hung, and the reinforcing frame was fixed to the resin molded body. The seat as shown in FIG. 1 was prepared by fixing the back or the back to the frame fixed to the vehicle. As shown in Table 2, the seating comfort obtained was good and the durability was sufficient for practical use. When the edge of the seat was exposed to the flame, the mesh began to burn along with the side and wadding layers, causing a drip, which suppressed the spread of the flame and immediately extinguished the flame. In the case of using a material having good flame retardancy, safety is ensured even in a fire.
[0029]
Example 2
Polyester-based thermoplastic elastomer obtained in the same manner as in Example 1 by charging 20 mol% of dimethyl isophthalate (DMI), 80 mol% of DMT and 1.4 butanediol (1.4 BD) with a small amount of a catalyst. Table 1 shows the resin formulation. Table 2 shows the characteristics of the mesh body obtained in the same manner as in Example 1 except that the nozzle of A-3 had a circular cross section having a hole diameter of φ1 mm in the orifice. The solid cross section was formed from filaments having a fineness of 9000 denier, and the average apparent density of the net was 0.043 g / cm. ³ Met. Then, the cushioning layer of the seat portion produced in the same manner as in Example 1 had an average apparent density of 0.056 g / cm. ³ The average apparent density of the back cushion layer is 0.053 g / cm. ³ Table 2 also shows the evaluation results of the seat obtained by using the cushion body of FIG. As is clear from Table 2, the heat resistance of the mesh body and the durability at room temperature are practically usable, the toxicity index of the combustion gas is low, and the cushioning material is highly safe. It can be seen that it has a cushioning function and is durable for practical use.
[0030]
Example 3
Polyurethane-based elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as a chain extender were added and polymerized, and then 2% of an antioxidant was added. Table 3 shows the formulation of the dried polyether-based urethane polymer.
[0031]
[Table 3]

[0032]
Table 2 shows the properties of the net obtained in the same manner as in Example 1 except that the melting temperature of the obtained thermoplastic elastic resin B-1 was 220 ° C. In Example 3, the filament of the mesh body of the cushion layer had a hollow cross section of a triangular conical shape with a hollow ratio of 41% and a fineness of 9800 denier, and the average apparent density was 0. 0.045 g / cm ³ It had a cushioning function with excellent heat resistance and durability at room temperature, and had a low toxicity index of combustion gas. Next, using a thermoplastic polyurethane film having a flow start temperature of 135 ° C. as the adhesive 12, laminating and compressing in the same manner as in Example 1 except that the fiber-full web was not used, setting the thermoforming temperature to 172 ° C., and annealing temperature. Was molded in the same manner as in Example 1 except that the average cushioning density of the cushion layer at the seat was 0.060 g / cm. ³ The average apparent density of the back cushion layer is 0.056 g / cm. ³ It can be understood that the seat of Example 3 obtained by using the cushion body of the above is an excellent seat which is excellent in sitting comfort utilizing characteristics of soft urethane and durable for practical use.
[0033]
Comparative Example 1
Comparative Example 1 had a fineness of 8800 denier and an apparent density of 8800 denier, except that the melting temperature was 270 ° C. except that polybutylene terephthalate (PBT) having a relative viscosity of 1.20 was used. 0.044g / cm ³ Table 2 shows the characteristics of the reticulated body. Then, the average apparent density of the cushion layer of the seat portion prepared in the same manner as in Example 2 except that the thermoforming temperature was set to 250 ° C. and the annealing for pseudo crystallization was not performed was 0.055 g / cm. ³ The average apparent density of the back cushion layer is 0.052 g / cm. ³ The seat of Comparative Example 1, which was obtained by using the cushion body of the above, is originally made of a mesh made of thermoplastic inelastic polyester having poor heat resistance and durability, and is therefore hard and uncomfortable to sit, and also has durability. This is an example of a bad seat.
[0034]
Comparative Example 2
The average apparent density of the cushion member at the seat portion was 0.062 g / cm using only the net formed in Example 2 without using the resin molded product and the fiber-fill web. ³ The average apparent density of the back cushion body is 0.056 g / cm. ³ The cushion body formed in the same manner as in Example 2 except that the cushion body was compression-molded, thermoformed, and rapidly cooled without annealing so that the resin molded body was not used. The surface finish is poor, and the characteristics of the obtained seat shown in Table 2 are examples of good seating comfort, but poor durability and poor seating durability.
[0035]
Comparative Example 3
Without using the mesh, only the fiber-fill web prepared in Example 1 was used for the cushion layer, and the average apparent density of the cushion layer was 0.062 g / cm. ³ The average apparent density of the back cushion body is 0.056 g / cm. ³ The characteristics of the seat shown in Table 2 were prepared using a cushion body prepared in the same manner as in Example 2 except that the laminate was compressed and thermoformed and rapidly cooled without annealing. Although the comfort is good, since a mesh made of a thermoplastic elastic resin having excellent heat resistance and durability is not used, the durability is inferior and this is an unpreferable example for a seat.
[0036]
Comparative Example 4
A fineness of 1800 denier was obtained in the same manner as in Example 2, except that a take-off conveyor net was placed 5 cm below the nozzle surface at a discharge rate of 180 g / min and the take-up speed was 1.2 m / min. Content of 9000 ppm (60A + 200 = 3320 ppm), average apparent density is 0.006 g / cm ³ The net density is 0.009 g / cm for the cushion layer at the seat and back. ³ The seat using the cushion body obtained in the same manner as in Example 2 except that the laminate was compressed and subjected to the pseudo-crystallization treatment so that the density was too low, the seating comfort was remarkably inferior, and the durability was inferior. This is an example.
[0037]
Comparative Example 5
The filaments were discharged at a discharge rate of 3 g / min per single hole and the filament fineness obtained in the same manner as in Example 2 except that the speed of the take-off conveyor net was set to 0.3 m / min. Density is 0.21 g / cm ³ The density of the cushion layer of the seat and the back is 0.25 g / cm ³ The seat obtained by using the cushion body prepared in the same manner as in Example 2 except that the laminate was compressed and thermoformed and rapidly cooled without annealing so that the seating comfort was high because the cushion layer was hard This is an example of slightly inferior and insufficient durability.
[0038]
Comparative Example 6
Discharge rate per single hole 25 g / min using a staggered orifice diameter φ2 mm nozzle with a pitch of 10 mm in the width direction and a pitch of 20 mm in the length direction on a nozzle effective surface of 50 cm in width and 5 cm in length And the fineness of the filament obtained in the same manner as in Comparative Example 2 was 113,000 denier, except that the take-up conveyor net was arranged 30 cm below the nozzle surface, and was taken at 1 m / min. Is 0.15g / cm ³ The net density of the cushion layer on the seat and back was 0.035 g / cm ³ The seat using the cushion body obtained in the same manner as in Example 2 except that the laminate was compressed and subjected to the pseudo crystallization treatment so that the mesh size was remarkably thick and had a density unevenness. This is an example of a seat that is less comfortable and has a slightly worse sitting comfort.
[0039]
Comparative Example 7
Table 2 shows some of the characteristics of the net obtained by the same method as in Example 2 except that a pseudo-crystallization treatment was not performed after the take-up conveyor net was arranged under the nozzle surface 60 cm and taken out. In addition, since the adhesion state was poor and the shape retention was poor, the repulsion force at 50% compression, the apparent density, the reinforcing effect, the residual strain at 70 ° C., and the repeated compression strain were not evaluated. Next, the mesh having the separated filaments was packed into a female mold, and the apparent density of the cushion layer was 0.055 g / cm. ³ The seat using the cushion body obtained in the same manner as in Example 2 except that the laminate was compressed and subjected to the pseudo-crystallization treatment so that the mesh line was not fused, so that the sitting comfort was poor. In this case, since the mesh shape is not fixed, the cushion material is greatly damaged and the durability is poor.
[0040]
Comparative Example 8
Using the reticulated body obtained in Example 2, a silicone oil film was applied to the surface of the resin molded article used in Example 1, and the apparent density of the cushion layer was 0.055 g / cm without using an adhesive. ³ The seat made by using a cushion body in which the resin molded body and the reticulated body obtained in the same manner as in Example 2 were laminated and compressed so that the pseudo-crystallization treatment was not performed so that The seat was not uncomfortable, but the durability was poor.
[0041]
【The invention's effect】
The seat of the present invention uses, as a cushion layer, a mesh formed by fusing and integrating filaments made of a thermoplastic elastic resin having good recoverability and vibration absorption, and a porous resin molded body having a depth equal to that of a conventional cushion body. Since the draw-formed part is joined and integrated with the cushion layer, the air permeability is improved, and the durability of the convex part and the shape retention of the cushion body are improved. It is an optimal seat that is excellent in vibration isolation, heat resistance and durability, shape retention and cushioning, is resistant to stuffiness and can be recycled without sorting. Further, in the cushion body using a conventionally known fiber-fill, it is difficult to perform deep drawing, and the forming is complicated. However, in the method of the present invention, the forming can be performed in one step by omitting the deep drawing. In addition, a useful seat can be provided at low cost by reducing the cost of molding processing. Of course, it is also useful for seats for ships, offices, furniture, etc. in addition to vehicles.
[Brief description of the drawings]
FIG. 1 is a schematic longitudinal sectional view of a seat according to the present invention.
FIG. 2 is a diagram showing a conceptual cross-sectional view of a back portion and a seat portion of the seat of the present invention.
FIG. 3 is a perspective view of a resin molded body used for the back of the seat of the present invention.
FIG. 4 is a perspective view of a resin molded body used for a seat portion of the seat of the present invention.
FIG. 5 is a view showing the concept of a forming process of the seat according to the present invention, and the process proceeds in the order of (A) → (B) → (C).
FIG. 6 is a view showing the concept of a forming process of the seat of the present invention, and the process proceeds in the order of (A) → (B) → (C).
[Explanation of symbols]
1: Side ground 2: Reticulated body
3: Resin molded body 4: Opening of resin molded body
5: Backing part 6: Reinforcement frame
7: Female mold 10: Male mold
11: fiber-fill web 12: adhesive layer,

Claims

The main part is a seat comprising a back portion and a seat portion formed by a side ground, a cushion layer, and a back side deep drawing shape portion, and the injection molded resin molded body having a seat back side deep drawing shape portion having an opening ratio of 10% or more. The cushion layer is made of a thermoplastic elastic resin in which continuous filaments having a fineness of 100,000 denier or less meander and are brought into contact with each other to form a three-dimensional three-dimensional structure in which most of the contact portions are fused. A seat comprising a mesh having an apparent density of 0.01 g / cm ³ to 0.2 g / cm ³ , wherein the resin molded body and the mesh are integrally joined by an adhesive or self-adhesion.

2. The seat according to claim 1, wherein a wading layer made of fiber-fill is disposed between the mesh and the side.

Dispose the mesh to be a cushion layer cut into a predetermined shape in the female mold, and arrange a resin molded body formed into a deep drawing shape to be the back or back on it, or between the mesh and the resin molded body An adhesive layer having a melting point lower by at least 10 ° C. than the melting point of the mesh body is provided, and the cushion layer is compressed from above with a male mold, and the protrusions are also compressed from the inside of the recesses via the resin molded body. After heating with a heating medium at a temperature 5 ° C. higher than the melting point to 50 ° C. lower than the melting point and integrating by thermoforming, once cooled or continuously, at least 10 ° C. higher than the glass transition temperature of the mesh body A method of manufacturing a seat, comprising attaching a side ground to a cushion molded body obtained by annealing at a temperature lower than the melting point by 20 ° C. or more, and fixing the cushion to a seat frame.

4. The method for manufacturing a seat according to claim 3, wherein a wadding layer is disposed between the cushion molded body and the side ground.