JP3620604B2

JP3620604B2 - Flame retardant seating and manufacturing method

Info

Publication number: JP3620604B2
Application number: JP17251194A
Authority: JP
Inventors: 英夫磯田; 靖司山田
Original assignee: Toyobo Co Ltd
Current assignee: Toyobo Co Ltd
Priority date: 1994-07-25
Filing date: 1994-07-25
Publication date: 2005-02-16
Anticipated expiration: 2020-02-16
Also published as: JPH0833782A

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、難燃性で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、難燃性を有し、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、前記樹脂成形体はクッション層を構成連続した線状の融点より２０℃以上高くなっており、クッション層がソフトセグメント量（Ａ重量％）と燐含有量（Ｂｐｐｍ）が６０Ａ＋２００≦Ｂの関係を満足する熱可塑性弾性樹脂からなる繊度が１０００００デニ−ル以下の連続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て３次元立体構造体を形成した見掛け密度が０．０１〜０．２ｇ／cm³の網状体で構成され、前記樹脂成形体と該網状体が接着剤又は該網状体の線条を高融点成分と低融点成分とからなる熱接着機能を付与した複合繊維とし自己接着により接合されており、表層に難燃性側地を配したことを特徴とする難燃性座席、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難燃性座席の製法である。
【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≦Ｂ≦１０００００の関係を満足する必要がある。満足しない場合は難燃性が劣るので好ましくない。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好ましくない。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、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、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。本発明の難燃性網状体は、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１０００ｐｐｍ以上２００００ｐｐｍ以下含有する。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好ましくない。好ましい燐含有量は２０００ｐｐｍ以上１００００ｐｐｍ以下、より好ましくは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好ましくない。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クッション層の融点より２０℃以上高い融点を持ち、難燃性を示す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燐含有量（Ｂｐｐｍ）がソフトセグメント量（Ａ重量％）とが６０Ａ＋２００≧Ｂを満足する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、表層に難燃性側地を配した座席（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。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、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。固体状の難燃剤は樹脂と共に乾燥混合して偏析しないように押出機に供給すれば簡単であるが、液状の難燃剤は樹脂を混練押出機に定量供給しつつ別途に液状の難燃剤も定量供給しつつ混練する方法を取るのが最も望ましい。例えば、二軸混練押出機のベント穴から液状難燃剤を定量供給する方法等が例示できる。このような方法で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．難燃性
Ｆ−ＭＶＳＳ３０２法により、難燃基準（６０秒以下で消炎する）を満たすものを合格、満たさないものを不合格と判定した。
９．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。
１０．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。
１１．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、二軸押出機に供給しつつ、トリス（２・４−ジ−ｔ−ブチルフェニル）ホスファイトを燐含有量が５０００ｐｐｍとなる量を添加して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、ＭＶＳＳ−３０２項の方法による難燃性が自消性であった。
【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に燐含有量８０００ｐｐｍとなるように難燃剤を添加し、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、燐含有量８０００ｐｐｍ（６０Ａ＋２００＝３３２０ｐｐｍ）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、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。また、座席の端を火炎に曝したがすぐに消炎した。
【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のみに燐含有量１２０００ｐｐｍとなるように難燃剤を添加し、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、燐含有量１２０００ｐｐｍ（６０Ａ＋２００＝２４８０ｐｐｍ）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、難燃性で、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。また、座席の端を火炎に曝したがすぐに消炎した。
【００３３】
比較例１
燐含有量で５０００ｐｐｍとなるように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オキシロを共重合した相対粘度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、燐含有量が５０００ｐｐｍで、燐含有量５０００ｐｐｍ、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、難燃性は有るが、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。なお、座席の端を火炎に曝したがすぐに消炎した。
【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
Ａ−３に燐含有量が１００ｐｐｍとなるように難燃剤を添加した以外、実施例２と同様にして得た線条の繊度が９０００デニ−ル、燐含有量が２００ｐｐｍ（６０Ａ＋２００＝３３２０ｐｐｍ）、見掛け密度が０．０４５ｇ／ｃｍ^３の網状体を用い、疑似結晶化処理をしなかった以外実施例２と同様にして得た座席は、座り心地は良好だが、耐久性がやや劣り、網状体が充分に難燃化されていないので座席の端を火炎に曝すと側地やワディング層は溶融するが、網状体がドリップせずに火炎が燃えひろがって座席は燃え尽きた。難燃性が不合格となる素材を用いた場合、火災時に危険な状態になる例である。
【００３７】
比較例５
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。
【００３８】
比較例６
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、燐含有量が９０００ｐｐｍ（６０Ａ＋２００＝３３２０ｐｐｍ）、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。
【００３９】
比較例７
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−ルで燐含有量が９０００ｐｐｍ（６０Ａ＋２００＝３３２０ｐｐｍ）、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。
【００４０】
比較例８
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。
【００４１】
比較例９
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。
【００４２】
【発明の効果】
本発明の座席は、回復性と振動吸収性の良い燐含有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、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。
【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 application fields]
The present invention relates to a vehicle seat having excellent cushioning properties, heat resistance and vibration absorption, flame retardant and recyclable, and a seat manufacturing method capable of omitting deep drawing when molding a cushion molded body. .
[0002]
[Prior art]
Currently, resin cushions or hard cottons bonded with urethane foam or crimped fibers are used as cushion layers for vehicle seats.
[0003]
However, seats using urethane foam as a cushion layer have extremely good durability, but are inferior in moisture permeability and heat storage, so they are easily stuffy, and they are not thermoplastic. Furnace damage is significant and toxic gas removal is expensive. As a result, landfills are often used. However, since it is difficult to stabilize the ground, there is a problem that the landfill site is limited and the cost increases. In addition, although moldability is excellent, there is a problem of pollution of chemicals used during production. Japanese Patent Laid-Open No. 63-77482 has been proposed as a method for improving steaming, but it is insufficient.
[0004]
As a seat with improved dampness, as a seat made of resin cotton in which a polyester fiber is bonded to a cushion layer with a rubber-based or urethane-based adhesive, for example, a rubber-based adhesive is used, Japanese Patent Laid-Open Nos. 60-11352 and 61 -141388 and JP-A-61-141391. Japanese Patent Application Laid-Open No. 61-137732 discloses a crosslinkable urethane. Seats using these cushion layers are inferior in durability, are not thermoplastic, have a single composition, cannot be recycled, and are troublesome during processing, especially deep drawing is difficult to finish. There is a problem that gets worse. There are also pollution problems of chemicals used during manufacturing.
[0005]
For example, JP-A-5-208470 and JP-A-5-220278 are made of polyester hard cotton with a thermal bonding fiber as an adhesive that can be recycled and produce a seat that generates 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 the adhesive component of the heat-bonding fiber used is a brittle amorphous polymer. Therefore, there is a problem that the adhesive part is inferior because the adhesive part is easily broken during use and the form and elasticity are lowered. As an improved method, a method of entanglement treatment has been proposed in Japanese Patent Application Laid-Open No. 4-245965 and the like, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is greatly lowered. In addition, there is also a problem that the bonded portion is difficult to deform and it is difficult to impart soft cushioning properties. In these methods, deep drawing is difficult. As a method to improve durability, a cushion material molded from polyester cotton using heat-bonded fibers using non-elastic polyester as a core component, using a polyester elastomer that softens the adhesive part and recovers even if deformed to some extent. Are 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 the elastomer, and improves the formation of the heat-bonding portion to form an amoeba-shaped bonding portion, but is easily plastically deformed. In addition, since the core component is non-elastic polyester, there is a problem that plastic deformation particularly under heating becomes remarkable, and heat resistance and compression resistance is lowered. As an improved method of these, Japanese Patent Application Laid-Open No. 5-163654 proposed a structure comprising only a heat-adhesive conjugate fiber using a polyester elastomer containing isophthalic acid as a sheath component and an inelastic polyester as a core component. However, for the reasons described above, plastic deformation under heating becomes significant, and the heat resistance and compression resistance is lowered, so that there is a problem in using it as a cushion material for a vehicle seat. On the other hand, in JP-A-5-337258, since the elastomer does not contain an amorphous component, the heat resistance is improved and the heat resistance is further improved by annealing. Since it contains, durability is still insufficient compared with polyurethane foam. Moreover, since the fiber is thermoformed, there is a problem that the complexity at the time of forming is not solved.
[0006]
Japanese Unexamined Patent Publication No. 47-44839 discloses a thermoplastic olefin network used for civil engineering work. However, since the material is olefin, the heat durability is remarkably inferior and cannot be used as a cushion material for a vehicle seat. Japanese Patent Laid-Open No. 1-207462 discloses a floor mat made of vinyl chloride. However, it is preferable as a cushioning material for a vehicle seat because it has poor compression recovery at room temperature and remarkably poor heat resistance. There is nothing. Note that the network structure is not considered at all regarding flame retardancy, vibration damping, and molding.
[0007]
[Problems to be solved by the invention]
Thermoplastic elastic resin that solves the above problems, shuts off vibration, has excellent heat resistance, shape retention, cushioning properties, is hard to stuffy, has flame retardancy, and has a low toxicity index of combustion gas and high safety It aims at providing the manufacturing method which simplified the vehicle seat which used the net-like body for the cushioning material, and deep drawing.
[0008]
[Means for Solving the Problems]
Means for solving the above-mentioned problem, that is, the present invention is a seat comprising a back part and a seat part formed from a side ground, a cushion layer, and a back face deep drawing shape part as main parts. It consists of an injection-molded resin molded body having an aperture ratio of 10% or more. The resin molded body is 20 ° C. higher than the linear melting point constituting the cushion layer, and the cushion layer has a soft segment amount (A weight). %) And phosphorus content (Bppm) satisfying the relationship of 60A + 200 ≦ B, the continuous filaments having a fineness of 100000 denier or less are twisted and brought into contact with each other, and most of the contact portions are The apparent density of the fused three-dimensional structure formed is 0.01 to 0.2 g / cm ^Three The resin molded body and the network body are adhesive or The filament of the network is a composite fiber having a high-melting-point component and a low-melting-point component and having a heat bonding function. A flame-retardant seat, which is bonded by self-adhesion and has a flame-retardant side surface on the surface, a net-like body serving as a cushion layer cut into a predetermined shape on a female mold, A resin molded body molded in a deep drawing shape to be the back surface or the back surface is disposed, or an adhesive layer having a melting point at least 10 ° C. lower than the melting point of the mesh body is disposed between the mesh body and the resin molded body, In addition, the cushion layer is compressed from above and the convex portion is also compressed from the inside of the concave portion through the resin molded body, and is heated with a heating medium having a temperature 5 ° C. higher than the melting point of the net-like body to 50 ° C. After being integrated by the above, the cushion molded body obtained by cooling once or continuously and annealing at a temperature of 10 ° C. higher than the glass transition temperature of the network and 20 ° C. lower than the melting point is applied to the side of the cushion molded body. And secure it to the seat frame It is a process for the preparation of flame-retardant seat which is characterized.
[0009]
The thermoplastic elastic resin in the present invention refers to a polyether glycol having a molecular weight of 300 to 5000, a polyester glycol, a polycarbonate glycol or a long chain hydrocarbon terminal as a soft segment. Examples thereof include polyester elastomers, polyamide elastomers, polyurethane elastomers, polyolefin elastomers and the like obtained by block copolymerization of acid or hydroxyl group olefin compounds. By using a thermoplastic elastic resin, it becomes possible to recycle by remelting, so that recycling becomes easy. For example, as a polyester 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. A block copolymer can be illustrated. 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, diphenyl 4,4 'dicarboxylic acid, etc. At least one dicarboxylic acid selected from alicyclic dicarboxylic acids such as 1,4 cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, and sebacic acid dimer acid, or ester-forming derivatives thereof. Species, aliphatic diols such as 1,4 butanediol, ethylene glycol, trimethylene glycol, tetremethylene glycol, pentamethylene glycol, hexamethylene glycol, 1,1 cyclohexane Diethanolol, alicyclic diols such as 1,4 cyclohexane dimethanol, or these At least one of diol components selected from the ester-forming derivatives, and polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 300 to 5,000. It is a ternary block 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 dicarboxylic acid, a diol and a polyester diol such as a polylactone having an average molecular weight of about 300 to 5,000. . Considering thermal adhesiveness, hydrolysis resistance, stretchability, heat resistance, etc., dicarboxylic acid is terephthalic acid, or

naphthalene

2,6 dicarboxylic acid, diol component is 1.4 butanediol, poly As the alkylene diol, a polytetramethylene glycol ternary block copolymer, or as the polyester diol, a polylactone ternary block copolymer is particularly preferable. In a special case, a polysiloxane-based soft segment can also be used. Also, the thermoplastic elastomer resin of the present invention includes those obtained by blending the above elastomer with a non-elastomer component, those obtained by copolymerization, those obtained by using a polyolefin-based component as a soft segment, and the like. As the polyamide elastomer, the hard segment has nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, etc. and their copolymer nylon as a skeleton, and the soft segment has an average molecular weight of about 300. A block copolymer composed of at least one of polyalkylenediols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and ethylene oxide-propylene oxide copolymer of ˜5000 alone or You may mix and use 2 or more types. Further, blended or copolymerized non-elastomer components can be used in the present invention. Polyurethane elastomers include (A) a polyester and / or polyester having a hydroxyl group at the terminal with a number average molecular weight of 1000 to 6000 in the presence or absence of a normal solvent (dimethylformamide, dimethylacetamide, etc.) (B A typical example is a polyurethane elastomer in which a chain is extended with a polyamine containing (C) a diamine as a main component to a prepolymer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with both ends being isocyanate groups. It can be illustrated as Polyesters and polyethers of (A) include polybutylene adipate copolymer polyester, polyethylene glycol, polypropylene glycol, polytetramethylene having an average molecular weight of about 1000 to 6000, preferably 1300 to 5000. Polyalkylenediols such as glycols and glycols composed of ethylene oxide-propylene oxide copolymers are preferred. As the polyisocyanate (B), conventionally known polyisocyanates can be used, but diphenylmethane can be used. An isocyanate mainly composed of 4 · 4 ′ diisocyanate may be used, and if necessary, a conventionally known triisocyanate or the like may be added in a small amount. As the polyamine (C), known diamines such as ethylene diamine and 1,2 propylene diamine are mainly used, and a trace amount of triamine and tetraamine may be used in combination as necessary. 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, which can maintain the heat durability, and more preferably 160 ° C. or higher because the heat durability is improved. In addition, since the network of the present invention contains a phosphorus compound to impart flame retardancy, the thermal stability is slightly inferior to those containing no flame retardant. It is particularly preferable to improve the property and durability. The antioxidant is preferably a hindered phenol type or hindered amine type as a hindered type antioxidant, and 1% to 5% of a hindered phenol type antioxidant containing no nitrogen. Addition to suppress thermal decomposition is particularly preferable because generation of toxic gas with a small lethality during combustion can be suppressed. The soft segment content 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 soft segment content of the component having the vibration and stress absorbing function of the elastic network of the present invention is preferably 15% by weight to 80% by weight, more preferably 30% by weight to 70% by weight. .
[0010]
The flame retardant network of the present invention is required to satisfy the relationship of 60A + 200 ≦ B ≦ 100000 with respect to the soft segment content (A wt%) in the phosphorus content (Bppm) in the thermoplastic elastic resin. If not satisfied, the flame retardancy is inferior, which is not preferable. If it exceeds 100000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic elastic resin is inferior. A preferable phosphorus content (Bppm) is 30A + 1800 ≦ B ≦ 100,000 with respect to the soft segment content (A wt%), and a more preferable phosphorus content (Bppm) is 16A + 2600 with respect to the soft segment content (A wt%). ≦ B ≦ 50000. Flame retardancy can be achieved by adding a large amount of halides and inorganics to provide a high level of flame retardancy, but it generates a large amount of toxic halogen gas that is low in lethality during combustion, causing the problem of poisoning in a fire. Yes, during incineration, damage to the incinerator is large and undesirable. In the present invention, the halide content is at least 1 wt% or less, preferably the halide content is 0.5 wt% or less, more preferably no halide. For example, in the case of a polyester-based thermoplastic elastic resin, the phosphorus-based flame retardant of the present invention is described in JP-A-51-82392 as a flame retardant in the hard segment portion at the time of resin polymerization. Carboxylic acids such as [2,3, di (2, hydroxyethoxy) -carbonylpropyl] 9,10, dihydro, 9, oxa, 10 phosphaphenalens, 10 oxiro as part of the acid component of the hard segment Flame retardancy by adding a phosphorous compound such as tris (2,4-di-t-butylphenyl) phosphite, for example, to a method of forming a polyester-based thermoplastic elastic resin or a post-process to the thermoplastic elastic resin Sex can be imparted. Other flame retardants that can impart flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as necessary. The flame retardant network of the present invention contains phosphorus in order to impart flame retardancy, and the reason for this is that, as described above, from the viewpoint of safety, cyan gas, halogen gas, etc. generated in the event of a fire The purpose is to reduce the amount of toxic gas with a low lethal amount as much as possible. For this reason, the toxicity index of the combustion gas of the flame retardant network of the present invention is preferably 6 or less, more preferably 5.5 or less. Moreover, when using a polyester fiber for a side land or a wadding layer, it is preferable to use a polyester-based thermoplastic elastic resin, which can be recycled and recycled without separation.
[0011]
The filament made of the thermoplastic elastic resin constituting the network of the present invention preferably has an endothermic peak below the melting point in the melting curve measured with a differential scanning calorimeter. Those having an endothermic peak below the melting point are significantly improved in heat and sag resistance than those having no endothermic peak. For example, as a preferable polyester-based thermoplastic resin of the present invention, those containing 90 mol% or more of terephthalic acid or

naphthalene

2,6 dicarboxylic acid having a rigid hard segment acid component, and more preferably terephthalic acid or The content of naphthalene 2.6 dicarboxylic acid is 95 mol% or more, particularly preferably 100 mol% and the glycol component is polymerized to the required degree of polymerization after transesterification, and is then preferably used as a polyalkylenediol. When polytetramethylene glycol having an average molecular weight of 500 or more and 5000 or less, particularly preferably 1000 or more and 3000 or less is 15% by weight or more and 70% by weight or less, more preferably 30% by weight or more and 60% by weight or less, Terephthalic acid or

naphthalene

2,6 dicarboxylic acid, which has a rigid acid component in the hard segment, When the amount is large, the crystallinity of the hard segment is improved, plastic deformation hardly occurs, and heat sag resistance is improved. However, after melting and heat bonding, annealing is performed at a temperature lower by at least 10 ° C. than the melting point. When treated, heat resistance and sag resistance are improved. Heat annealing resistance is further improved by annealing after applying compressive strain. An endothermic peak is more clearly expressed at a temperature not lower than room temperature and not higher than the melting point in a melting curve obtained by measuring the filaments of the network structure thus treated with a differential scanning calorimeter. When annealing is not performed, the endothermic peak does not appear in the melting curve above the room temperature and below the melting point. By analogy with this, it is considered that the hard segments are rearranged by annealing and pseudo-crystallization-like cross-linking points are formed, and the heat resistance and sag resistance are 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 fabric and resin molded body used in the seat of the present invention include polyester, polyamide, and polyolefin. In the present invention, it is preferable to use a glass transition temperature of at least 40 ° C. or higher. For example, in polyester, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), poly Examples include butylene terephthalate (PBT), polybutylene naphthalate (PBN), polyarylate, and their copolyesters. Examples of the polyamide include polycaprolactam (NY6), polyhexamethylene adipamide (NY66), polyhexamethylene sebacamide (NY6-10) and the like. 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 for the side of the cushion material, and therefore, PET and PEN having good heat resistance as cushion materials that can be recycled without being separated when discarded. Polyester such as PBN and PCHDT is particularly preferable. When used in a resin molded product, components that improve impact resistance within a range that retains the required strength, such as thermoplastic elastic resin, PBT having a low glass transition temperature, polypropylene terephthalate (PPT), and polyhedron. It is preferable to add less than 5% of xylene terephthalate or the like. The network having flame retardancy of the present invention contains a phosphorus content of 1000 ppm to 20000 ppm in the thermoplastic inelastic resin. If it is less than 1000 ppm, the flame retardancy is insufficient, and if it exceeds 200000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic inelastic resin is inferior. A preferable phosphorus content is 2000 ppm or more and 10,000 ppm or less, more preferably 3000 ppm or more and 8000 ppm. Flame retardancy can be achieved by adding a large amount of halides and inorganics to provide a high level of flame retardancy, but it generates a large amount of toxic halogen gas that is low in lethality during combustion, causing the problem of poisoning in a fire. Yes, during incineration, damage to the incinerator is large and undesirable. In particular, vinyl chloride has a self-extinguishing property, but generates a lot of toxic gas when burned, so it is not preferable to use it in the present invention. In the present invention, the halide content is at least 1 wt% or less, preferably the halide content is 0.5 wt% or less, more preferably no halide. As the phosphorus flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic inelastic resin, 10 [2-3.3] described in, for example, JP-A-51-82392 is used as a flame retardant during resin polymerization. Polyester thermoplastic inelastic resin obtained by copolymerization of carboxylic acid such as di (2, hydroxyethoxy) -carbonylpropyl] 9,10, dihydro, 9, oxa, 10 phosphaphenalene, 10 oxiro as part of acid component In a post-process at the time of injection molding of a thermoplastic inelastic resin, for example, a phosphorus compound such as tris (2,4-di-t-butylphenyl) phosphite is added to impart flame retardancy. be able to. Other flame retardants that can impart flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic inelastic resin as necessary. The cushion body constituting the seat of the present invention contains phosphorus in order to impart flame retardancy. As described above, the reason for this is that, from the viewpoint of safety, cyan gas and halogen gas generated during a fire are included. The purpose is to reduce the amount of toxic gas with a low lethal amount as much as possible. For this reason, the toxicity index of the combustion gas of the cushion body constituting the seat of the present invention is preferably 6 or less, more preferably 5.5 or less. Further, it is possible to recycle and recycle without sorting by using a polyester-based thermoplastic inelastic resin for the side land or the wadding layer.
[0013]
The present invention comprises a resin molded body having a melting point that is 20 ° C. higher than the melting point of an injection-molded cushion layer in which the rear surface of the seat or the rear surface of the seat has an aperture ratio of 10% or more, and exhibits flame retardancy. Phosphorus content (Bppm) in which the layer is formed by twisting continuous filaments having a fineness of 100000 denier or less and bringing them into contact with each other to form a three-dimensional structure in which most of the contact portions are fused. (A weight%) is an apparent density of 0.01 g / cm made of a thermoplastic elastic resin satisfying 60A + 200 ≧ B ³ To 0.2 g / cm ³ The resin molded body and the mesh body are integrally joined by an adhesive or self-adhesion, and the surface layer is provided with a flame retardant side surface (FIG. 1 is a sectional view of the seat, FIG. 2) (A) 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 invention. The seat of the present invention is a resin molded body (the resin molded body for the seat portion shown in FIG. 3 and the resin molded body for the back portion shown in FIG. The resin molded body is formed by joining and integrating the local stress received from the cushion layer made of a net-like body having excellent elasticity and recoverability made of a thermoplastic elastic resin. It is necessary to have a reinforcing function to be received at, and also to function as a convex core material such as a side portion. When the mesh body and the resin molded body are not joined and integrated, if the mesh body is subjected to a large deformation, the mesh structure may be destroyed, which is not preferable. The shape of the resin molding is preferably a pressure-resistant structure, for example, one having a reinforcing beam structure or one having a hollow structure. As a result, the number of frame members made of metal can be reduced and the weight can be reduced. It is not preferable that the back surface of the seat or the deep-drawn shape portion of the back surface is a cushion layer because a non-woven reinforcing layer and a metal reinforcing frame are required, which increases the seat weight. Therefore, the resin molded body needs to allow the heating fluid to penetrate during molding processing described later, and to have a hole area ratio of 10% or more for maintaining air permeability when using the seat. If it is less than 10%, the temperature rising rate at the time of molding becomes slow, which is not preferable because of local thermal deterioration or poor shape formation. In addition, even if the air permeability of the mesh body is good, it is not preferable because the back surface is insufficiently ventilated because it tends to be steamed. For the purpose of preventing stuffiness, the side portion may not have an opening portion, but preferably has an opening portion on the entire surface. The porosity of the resin molded body 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 a continuous filament having a fineness of 100,000 denier or less is twisted and brought into contact with each other to form a three-dimensional structure in which most of the contact portion is fused. Apparent density 0.01g / cm ³ To 0.2 g / cm ³ Therefore, the vibration applied from the outside is absorbed and attenuated by the vibration absorption function of the thermoplastic elastic resin, and even when a large deformation stress is applied locally, The surface is substantially flattened by thermoforming, and most of the contact portion is fused. The cushion layer receives the deformation stress, disperses the deformation stress, and the filament made of thermoplastic elastic resin is a three-dimensional solid. Since the structure is formed and fused and integrated with the resin molded body having a reinforcing function, the entire structure is easily deformed by holding the seat structure, and the net structure is easily deformed by the energy conversion. When it is absorbed and the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original form, so that the sag resistance is good. A net-like body composed only of known inelastic resins only has no rubber elasticity, and therefore is not recovered due to plastic deformation caused by compressive deformation, resulting in poor durability. In the case where the filaments of the mesh are not continuous, the adhesion point becomes a stress transmission point, so that a significant stress concentration occurs at the adhesion point, resulting in structural failure and the above-mentioned prior art. No. 1, JP-A 61-137732, WO 91-19032 and the like, which are not preferable because of their poor heat resistance and durability. In addition, hard cotton using a matrix made of a non-elastic resin as a matrix is not preferable for use in a cushion layer because plastic deformation occurs and the sag resistance is poor. If it is not fused, the shape cannot be maintained, and the structure does not deform integrally. Therefore, a fatigue phenomenon due to stress concentration occurs and the durability is inferior. At the same time, the shape is deformed and the body cannot be maintained. . A more preferable degree of fusion of the present invention is a state in which most of the portions in contact with the filaments are fused, and most preferably, the contact portions are all fused. The function of the cushion material is that the basic cushion layer is a layer that is slightly thicker and harder and has a body shape retention, and a layer that absorbs vibration with a slightly higher density with a component with good vibration damping and blocks vibration. The surface layer is a slightly softer layer with a slightly thinner fineness and a larger number of striated lines, giving a comfortable touch of the buttocks by moderate sinking and uniformly distributing the pressure distribution of the buttocks. 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, stress and vibration can be deformed and absorbed to improve the sitting comfort. Thus, a continuous filament made of a thermoplastic elastic resin with good vibration absorption and elastic recovery forms a three-dimensional structure in which most of the contact portion is fused, and the surface is substantially flat. Cushion body in which a molded resin layer with a reinforcing function is integrally bonded to the back surface of the cushion layer and the cushion layer by adhesive or self-adhesion, the surface layer receives deformation stress on the surface and improves the dispersion of stress. Reduces the stress applied to the linear shape and is supported by the resin molded body, deforms while retaining the entire shape of the network structure, absorbs the deformation stress, improves the cushioning properties that support the heel, and recovers when the stress is released In addition, the vibration transmitted from the frame is absorbed by the cushion layer made of thermoplastic elastic resin with good vibration absorption and elastic recovery, and the vibration of the resonance part of the human body is cut off to improve the comfort and durability. Can. The fineness of a filament made of a thermoplastic elastic resin having good vibration absorption and elastic recovery that forms the network of the present invention is 100,000 denier or less. Apparent density 0.2g / cm ³ In the following cases, if the density exceeds 100,000 deniers, the number of constituents decreases, density spots are generated, a partially inferior durability structure is formed, fatigue due to stress concentration is increased, and durability is lowered, which is not preferable. The fineness of the filaments made of the thermoplastic elastic resin of the present invention is 100 denier or more because if the fineness is too thin, the compressibility is too low and the stress absorption due to deformation is reduced, resulting in a decrease in the number of components. It is 50000 denier or less which does not impair the denseness of the structural surface. More preferably, it is 500 denier or more and 10,000 denier or less. The average apparent density of the network of the present invention is 0.005 g / cm. ³ In this case, the repulsive force is lost, the vibration absorption capacity and the deformation stress absorption capacity are insufficient, and it may be difficult to develop the cushion function. 0.25 g / cm ³ In the above, since the repulsive force may be too high and the sitting comfort may be deteriorated, the function as a cushion body is easily expressed by utilizing the vibration absorbing ability and the deformation stress absorbing function. ³ 0.20 g / cm ³ Or less, preferably 0.03 g / cm ³ 0.08 g / cm ³ It is as follows. In the present invention, a method of forming a different fineness laminated structure having an optimum configuration in combination with the apparent density of linear shapes having different finenesses can also be selected as a preferred embodiment. The thickness of the network of the present invention is not particularly limited. However, if the thickness is less than 5 mm, the stress absorption function and the stress dispersion function are lowered. Therefore, the preferred thickness can express the surface function for dispersing force and the vibration and deformation stress absorption 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 for joining and integrating the resin molded body and the mesh body of the seat of the present invention, the adhesive is preferably a resin having good adhesion to both the mesh body and the resin molded body. In particular, those having thermal adhesiveness are preferable. As a particularly preferred embodiment, for example, when the network is a polyester-based thermoplastic elastic resin and the resin molding is a polyester-based thermoplastic elastic resin or a polyester-based thermoplastic inelastic resin, at least the network-shaped thermoplastic elastic resin is used. A polyester resin having a melting point that is 10 ° C. or more lower than the melting point is preferable. Preferably, the melting point is 20 to 50 ° C. lower than the melting point of the network. In order to withstand the deformation of the cushion layer, a thermoplastic elastic resin is particularly preferable. The form of the adhesive is not particularly limited, but there are methods such as applying a film, a nonwoven fabric, a powder or a solution. However, a nonwoven fabric is particularly preferred because hot air is penetrated from the handling. As the nonwoven fabric, a spunbond nonwoven fabric, a melt blown nonwoven fabric or a short fiber nonwoven fabric made of a thermoplastic elastic resin 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 of filaments having a high-melting-point component and a low-melting-point component sheath / core structure or a side-by-side structure. In the case where the reticulate filaments have a composite structure, a preferable heat bonding function can be provided. For example, in the case of a sheath core structure, a thermoplastic elastic resin having a large soft segment content that can easily convert the vibration and deformation stress of the sheath component into a large amount is used as a thermal adhesive component, and the soft component containing the core component has an anti-compression property. Thermo-adhesive function by using a thermoplastic elastic resin with a small amount as a high-melting-point component for providing a network-like holding function, with the melting point of the heat-bonding component being 10 ° C. lower than the melting point of the high-melting-point resin Can also be granted. It is also preferable to laminate the surface layer of the flame-retarded reinforced network of the present invention with a low-melting-point thermoplastic elastic resin having a large soft segment content that can easily convert vibration and deformation stress as a heat-adhesive component. Adhesive function can be added. The melting point of the thermoadhesive component that forms the filaments in the network that is preferable for exhibiting the thermoadhesive function is a melting point that is 15 ° C to 50 ° C lower than the melting point of the high melting point component, and more preferably a melting point that is 20 ° C to 40 ° C lower. is there. The seat of the present invention having a cross section shown in FIG. 1, for example, having a cross-section as shown in FIG. This is an excellent sultry vehicle seat. In addition, it is especially preferable to use a flame retardant side for the seat of the present invention from the viewpoint of safety.
[0014]
It is preferable to dispose a wadding layer made of fiber-fill between the mesh body and the side ground of the seat according to the present invention because it has an effect of softening the touch of the seat. The wading layer is particularly preferable when the heat-bonding fiber is made of a thermoplastic elastic resin because the heat durability and cushioning properties are improved. When a fiber made of a thermoplastic inelastic resin is used as the heat-bonding fiber, the heat resistance durability is poor, which is not preferable. When using the wading layer as a thermal adhesive component between the side fabric and the cushion layer, by using fibers made of a thermoplastic elastic resin having a melting point that is at least 10 ° C. lower than the melting point of the thermoplastic elastic resin of the network. This is a preferred embodiment because the network structure can be maintained and thermal bonding with the network body and the side ground becomes possible.
[0015]
In the present invention, the cross-sectional shape of the reticulate filament is not particularly limited, but a hollow cross-section or an irregular cross-section is particularly preferable because it can provide a preferable anti-compressibility (repulsive force) and touch. The anti-compressibility can be adjusted according to the fineness and the modulus of the material used, and the fineness can be made thin.With a soft material, the hollowness and profile 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 gives the anti-compressibility with a good sitting comfort by lowering the hollowness and the profile. As another effect of the hollow cross section and the deformed cross section, by increasing the hollow ratio and the degree of deformity, when the same anti-compression property is given, the weight can be further reduced, 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 preferable anti-compressibility (repulsive force) and touch, there is a method in which the filaments of the present invention have a composite structure. Examples of the composite structure include a scissor structure, a side-by-side structure, and a combination structure thereof. However, in order to obtain a three-dimensional three-dimensional structure that can recover vibrations and deformation stresses that cannot be energy-converted even if the cushion layer is largely deformed, it is possible to soften 50% or more of the linear surface with a soft thermoplastic elastic resin. And a scissor structure or a side-by-side structure and a combination structure thereof. That is, in the sheath structure, the sheath component is a thermoplastic elastic resin with a high soft segment content that can easily convert vibration and deformation stress into energy, and the core component is a heat with a low soft segment content that exhibits anti-compression properties. 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, vibration and deformation stresses are easily converted into energy, and the melt viscosity of a thermoplastic elastic resin with a high soft segment content is set lower than the melt viscosity of a thermoplastic elastic resin with a low soft segment content and exhibiting anti-compressibility. Structure with a large proportion of thermoplastic elastic resin with a large soft segment content occupying a linear surface (metaphorically a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath / core sheath) The ratio of the thermoplastic elastic resin having a high soft segment content occupying a linear surface is particularly preferably 80% or more, and most preferably the thermoplastic elastic resin having a high soft segment content occupying a linear surface. The score is 100%. If the proportion of the thermoplastic elastic resin with a large soft segment content occupies the linear surface increases, the fluidity when melted and fused becomes high, which has the effect of strengthening the adhesion, and the structure deforms integrally. In this case, fatigue resistance against stress concentration at the adhesion point is improved, and heat resistance and durability are further improved.
[0016]
Next, the production method of the present invention will be described. Since the reticulate according to the present invention is not known at the time of the present invention, its production method will be described in detail. A thermoplastic elastic resin satisfying the relationship of 60A + 200 ≦ B ≦ 100000 in soft segment amount (A weight%) and phosphorus content (Bppm) is distributed to each nozzle orifice from a multi-row nozzle having a plurality of orifices. At a melting temperature of 20 ° C. or more and less than 80 ° C. higher than the melting point of the resin, it is discharged downward from the nozzle, and brought into contact with each other in the molten state and fused to form a three-dimensional structure. Cool in a bath to obtain a continuous network. In the present invention, as described above, there are a method in which a phosphorus compound is added and copolymerized during polymerization, and a method in which a phosphorus compound is added after polymerization and mixed and kneaded. The mixing and kneading can be performed by using a twin screw kneading extruder or a single screw extruder having a kneading function such as a dull mage or a pin, and can be performed before or after melt extrusion. If the flame retardant can be supplied in a fixed amount, kneading at the time of melt extrusion is the cheapest method. Solid flame retardant is easy to dry and mixed with resin and fed to the extruder so as not to segregate, but liquid flame retardant is quantitatively supplied separately to the liquid flame retardant while supplying the resin to the kneading extruder. It is most desirable to use a method of kneading while supplying. For example, a method of quantitatively supplying a liquid flame retardant from a vent hole of a twin-screw kneading extruder can be exemplified. By such a method, a soft segment amount (A wt%) and a phosphorus content (Bppm) satisfying the relationship of 60A + 200 ≦ B ≦ 100,000 are added to the thermoplastic elastic resin, and then melt-extruded to form a network. Form the body. The molten phosphorus-containing thermoplastic elastic resin is supplied to a multi-row nozzle having a plurality of orifices and discharged downward from the orifices. When the filaments are combined, the thermoplastic elastic resins melted and kneaded separately from a number of extruders are mixed and flowed so as to be combined immediately before the orifices of the multi-row nozzles and discharged downward. In the score, the core component is supplied from the center, and the sheath component is merged and discharged from the center. On the side-by-side, the components are combined and discharged from the left and right or front and rear. The melting temperature at this time is higher by 10 to 80 ° C. than the melting point of the thermoplastic elastic resin. (When combined, the same melting temperature is preferably 10 ° C. 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.) The melting temperature is higher than 80 ° C. above the melting point of the thermoplastic elastic resin. Then, thermal decomposition becomes remarkable and the rubber elastic property of the thermoplastic elastic resin is lowered, which is not preferable. On the other hand, if it is not higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and normal filaments cannot be formed. It is not preferable because the temperature is lowered and the filaments are not fused to each other, and a reticulated body may be formed. A preferred melting temperature is a temperature 25 to 60 ° C. above the melting point, more preferably a temperature 30 to 40 ° C. above the melting point. The shape of the orifice is not particularly limited, but a hollow cross section (for example, a triangular hollow, a round hollow, a hollow with a protrusion, etc.) and a deformed cross section (for example, a triangular, Y, star, etc.) In addition to the above effects, the three-dimensional structure formed by the melted discharge filaments makes it difficult for the flow to relax, and conversely maintains a long flow time at the contact point to strengthen the adhesion point. This is particularly preferable. In the case of heating for adhesion described in JP-A-1-2075, the three-dimensional structure is easy to relax, and a planar structure is formed, making it difficult to form a three-dimensional structure. As an effect of improving the properties of the net-like body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved. In the hollow cross section, if the hollow ratio exceeds 80%, the cross section tends to be crushed. Therefore, it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less, in which the effect of weight reduction can be exhibited. The pitch between the holes of the orifices needs to be a pitch that can sufficiently contact the loop formed by the linear shape. The pitch between holes is shortened to obtain a dense structure, and the pitch between holes is increased to obtain a dense structure. The pitch between holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different density and different fineness can be achieved as desired. The different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is changed, and a method in which both the pitch between rows and between holes are also changed. Also, if the cross-sectional area of the orifice is changed to give a pressure loss difference at the time of discharge, the discharge amount of the molten thermoplastic elastic resin pushed out from the same nozzle at a constant pressure is reduced as the orifice with a larger pressure loss is used. A network structure composed of different fineness filaments can be manufactured using a nozzle having at least a plurality of rows having different sectional areas of orifices in the longitudinal section. Next, discharging from the nozzle downward, forming a loop, bringing them into contact with each other in a molten state to form a three-dimensional structure, sandwiching both sides of the joined network structure with a take-off net, The surface of the reticulated body is bent and bent at 45 ° or more to flatten the surface, and at the same time, the contact point with the unbent discharge line is adhered to form a structure and then continuous Then, quenching with a cooling medium (usually using water at room temperature is preferable because the cooling rate can be increased and the cost can be reduced) to obtain a network having the three-dimensional solid network structure of the present invention. The distance between the nozzle surface and the take-off point is preferably at least 40 cm or less to prevent the discharge filament from being cooled and the contact portion from being fused. When the discharge amount of the discharge filament is 5 g / minute or more, 10 cm to 40 cm is preferable, and when the discharge amount of the discharge line is less than 5 g / minute, 5 cm to 20 cm is preferable. The thickness of the network is determined by the opening width of the take-up net (interval between take-up nets) that sandwiches both surfaces of the three-dimensional structure in the molten state. In the present invention, the opening width of the take-up net is set to 5 mm or more for the reason described above. Next, draining and drying are not preferred, but adding a surfactant or the like to the cooling medium is not preferable because draining or drying becomes difficult or the thermoplastic elastic resin swells. The desired loop diameter and wire diameter can be determined by the distance between the nozzle surface and the take-up conveyor installed on the cooling medium for solidifying the resin, the melt viscosity of the resin, the orifice diameter and the discharge amount, and the like. A pair of take-up conveyors with adjustable spacing installed on the cooling medium sandwich the molten discharge line and stop it, and continuously draw it into the cooling medium while fusing the parts that are in contact with each other. When the body is formed, by adjusting the interval of the conveyor, the thickness can be adjusted while the fused network 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 before the fusion points are sufficiently formed, resulting in insufficient fusion of the contact portions. Further, if the speed is too slow, the melt stays too much and the density becomes high, so it is necessary to set a conveyor speed suitable for the desired apparent density. The net thus obtained is then punched into a shape that matches the cushion shape of the seat to obtain a cut net having a predetermined shape. When using a net-like body for a cushion layer, it is necessary to select the resin used, the fineness, the loop diameter, and the bulk density depending on the purpose of use and the site of use. For example, in order to give a soft touch, moderate subsidence, and a stretchy bulge, it is preferable to use a low density, fine fineness, and a fine loop diameter. Medium density, thick fineness, slightly larger loop diameter layer to lower the frequency, linearly change the appropriate hardness and hysteresis during compression to improve body shape retention and durability It is preferable to have a structure in which layers of low density, fine fineness, and fine loop diameter are laminated and integrated. In addition, it is processed into a molded product from the manufacturing process within the range that does not degrade the performance even outside the resin manufacturing process, and flame retardant, insect proofing, heat resistance, water and oil repellency, coloring, aroma, etc. It is possible to perform processing such as adding a drug to impart the function.
On the other hand, the resin molded body is obtained by, for example, biaxial extrusion using a thermoplastic elastic resin, a thermoplastic inelastic resin, or a mixture thereof, and a necessary modifier such as a flame retardant using a general known injection molding machine. The molten resin melt-mixed using a machine is extruded into, for example, a mold having the shape shown in FIGS. 3 and 4 and cooled to obtain an injection molded body. Mold temperature at the time of resin extrusion is lower than the melting point of the resin by 30 ° C. than the melting point of the resin. This is desirable because the adhesion with the net is strong.
[0017]
Next, in the seat of the present invention, a net-like body serving as a cushion layer cut into a predetermined shape is disposed on the female mold, and a resin molded body molded in a deep-drawn shape serving as the back surface or the back surface is disposed thereon, or An adhesive layer having a melting point that is at least 10 ° C. lower than the melting point of the mesh body is disposed between the mesh body and the resin molded body, and the cushion layer is compressed from above with a male mold and also protrudes from the inside of the recess through the resin molded body. After compressing the part and heating with a heating medium having a temperature 5 ° C. higher than the melting point of the mesh body to 50 ° C. lower than the melting point and integrating by thermoforming, the glass is once cooled or continuously. A cushion is obtained by annealing at a temperature of 10 ° C. higher than the transition temperature and 20 ° C. lower than the melting point, and is attached to a seat frame and fixed to a seat frame. Hereinafter, the forming 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 the female mold 7 having the vent holes 8, and then opened as shown in FIG. 5 (B). A resin molded body 3 having a hole 4 is placed thereon, and then the mesh body 2 is wound up to the back side of the resin molded body 3 and hooked on a hook 9 that stops the mesh body 2 on the back side of the resin molded body 3. Stop body 2. Next, as shown in FIG. 5 (C), compression is performed with the male mold 10 having the vent holes 8. By compressing from above with the male mold 10, the convex portion 3 ′ of the resin molded body 3 transmits the 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 neatly 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. The temperature of the heating fluid at this time is such that a part of the mesh body is plastically relaxed and deformed into the shape of the seat, and the resin molded body is heated to a temperature at which the resin molded body and the mesh body can be thermally bonded. For example, (Example 1) When the mesh body has a single composition, it is heated at a temperature 5 ° C. higher than the melting point of the mesh body to melt the surface of the filament of the mesh body and thermally bond it to the resin molded body. When the temperature is higher by 10 ° C. or more than the melting point of the net-like body, the shape of the net-like body collapses and the cushion function is lowered, which is not preferable. When the mesh body is composed of filaments having a sheath core structure, for example, (Example 2) thermoforming at a temperature 5 ° C. or more higher than the melting point of the sheath component to 5 ° C. higher than the melting point of the core component of the mesh body Thus, this is a preferable example in which the net-like structure can be retained, can be formed into a desired seat shape, and thermal adhesion with the resin molded body can be strengthened. A temperature at which the core component does not plastically deform, 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 network has a single composition and an adhesive is used, (Example 3) The adhesive is applied to the surface of the resin molded body 3 in advance before being set in FIG. 6) Even when the thermobonding nonwoven fabric 12 is laminated and thermoformed as shown in FIG. 6, for example, a resin or melt blown nonwoven fabric 12 made of a thermoplastic elastic resin having a melting point of 160 ° C., the

nets

2 and 2 ′. When the melting point is 220 ° C., the heating temperature is preferably 170 ° C. or higher and 225 ° C. or lower. (Example 5) FIG. 6 shows a case where a fiber-fill is used for the wadding layer 11 as an example of the embodiment of the present invention. For example, FIG. 6 shows a fiber-fill web using a polyester-based thermoplastic elastic resin as a heat-bonding component. When the melting point of the thermal adhesive component is 185 ° C., the fiber-fill web base material 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

nets

2 and 2 ′ are 220 ° C. Thermoforming is preferably performed at a temperature that is 10 ° C. higher than the higher melting point of the thermal bonding component, 185 ° C. and 5 ° C. higher than the melting point of the network, that is, 195 ° C. to 225 ° C. If the temperature raising time is not within 15 minutes, the thermal decomposition of the low melting point component is promoted, the adhesion function is lowered, and the productivity is lowered, which is not preferable. 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, molding is performed, and then cooling is performed. As a preferable method of the present invention, a temperature higher than the glass transition temperature of the thermoplastic elastic resin by 10 ° C. or more and at least 10 ° C. higher than the glass transition temperature of the thermoplastic elastic resin in an arbitrary process that is continuously or once cooled and then integrally molded and commercialized. A more preferable production method is 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 is equal to or higher than the Tan dispersion α dispersion rising temperature (Tαcr) which is the glass transition temperature of the hard segment. By this treatment, the heat sag resistance is remarkably improved from those having an endothermic peak below the melting point and not having a pseudo crystallization treatment (no endothermic peak). The preferred pseudocrystallization temperature of the present invention is from (Tαcr + 10 ° C.) to (Tm−20 ° C.). In the case of continuous annealing, for example, in Example 1, it is cooled to a glass transition temperature + 10 ° C. or more and a temperature 20 ° C. or more lower than the melting point, held for 5 minutes or more, and then cooled to less than 50 ° C. Remove the cushion body 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., preferably less than 150 ° C. for 5 to 10 minutes. Is good. In Example 2, the glass transition temperature of the core component from a temperature 20 ° C. or more lower than the melting point of the sheath component, for example, 60 ° C. when the melting point of the sheath component is 185 ° C. and the glass transition temperature of the core component is 50 ° C. The annealing is preferably performed at a temperature of 100 ° C. or higher and 165 ° C. or lower, preferably 130 ° C. or lower. In Example 3, Example 4, and Example 5, it is preferable to anneal at 60 ° C. or higher, preferably 100 ° C. or higher and 140 ° C. or lower, preferably 130 ° C. or lower. Once cooled, the same effect is manifested by annealing non-continuously. Thus, a cushion body with improved heat and sag resistance can be obtained even if it is pseudo-crystallized by simple heat treatment. However, it is more preferable that the heat resistance and sag resistance are remarkably improved by separately applying 10% or more of compressive deformation and annealing. The cushion body thus obtained is covered with the side cloth 1, and is preferably covered with a flame retardant side cloth, for example, a polyester moquette made of Toyobo Co., Ltd. flame retardant polyester fiber heim. Accordingly, the side ground is stopped on the back side of the cushion body, and the side ground 1 is attached to the cushion surface. From the concave portion of the cushion body, for example, Japanese Utility Model Laid-Open Nos. 56-101071 and 60-109499 are disclosed. After the resin molded body 3 is penetrated with the pull-in button disclosed in the above, the side ground is suspended, or a known hanging method, for example, a hanging jig is set in advance on the convex portion of the female mold 7 and thermoformed. Further, it is possible to adopt a method in which the side ground 1 is fixed to the cushion body by fixing the resin molded body 3 or the reinforcing frame 6 from the concave portion of the cushion body. Then, the seat of the present invention is obtained by being fixed to the set frame of the seat.
[0018]
The seat of the present invention uses a mesh-like body made of a thermoplastic elastic resin with good recovery and vibration absorption for the cushion layer, and the porous resin molded body constitutes a deep-drawing molded portion in the conventional cushion body, Improves breathability, achieves the core material effect 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 isolation, heat resistance and shape retention It is a highly safe seat that has excellent performance and cushioning properties, is resistant to stuffiness, has flame retardancy, and has a low toxicity index for combustion gases. Moreover, in the cushion body using a conventionally known fiber-fill, deep drawing is difficult and molding is complicated, but in the method of the present invention, deep drawing can be omitted and molding can be performed in one step. Therefore, the cost of the molding process can be reduced, and a useful seat can be provided at a low cost. Of course, it is also useful for seats for ships, offices, furniture, etc. in addition to vehicles.
[0019]
【Example】
The present invention is described in detail below with reference to examples.
[0020]
In addition, evaluation in an Example was performed with the following method.
1. Melting point (Tm) and endothermic peak below melting point
The endothermic peak (melting peak) temperature was determined from the endothermic curve measured at 20 ° C./min using a TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu Corporation.
2. Tαcr
The polymer was heated to the melting point + 10 ° C. to prepare a film having a thickness of about 300 μm, and Tan δ (imaginary elastic modulus M ”measured at 110 Hz with a heating rate of 1 ° C./min using an orientec Vibron DDVII type. The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of the ratio M ″ / M ′) of the elastic part and the real part M ′ of the elastic modulus.
3. Apparent density
The sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is obtained, and the weight of the sample is shown as a value that is gradually reduced by the volume. (Average value of n = 4)
4). Fineness of filament
Samples are cut out from 10 locations, embedded in acrylic resin, cut into cross sections, cut into sections, and cross-sectional photographs are obtained. The cross-sectional area (Si) of each part is obtained from the cross-sectional photograph of each part. Further, an acrylic resin is dissolved in acetone in the same manner, vacuum degassed, and the specific gravity (SGi) measured at 40 ° C. using a density gradient tube is obtained. Next, a linear weight of 9000 m is obtained from the following equation. (Unit: cgs)
Fineness = [(1 / n) ΣSi × SGi] × 900000
5. Fusion
Whether the sample is fused by visual judgment or not is determined by pulling the bonded fibers by hand or not by whether or not the sample is fused.
6). Heat resistance (70 ° C residual strain)
The sample was cut into a size of 15 cm × 15 cm, compressed to 50%, left to stand in dry heat at 70 ° C. for 22 hours and then cooled to obtain the thickness (b) after standing for 1 day after removing the compression strain. ) From the following equation, that is, ((ab) / 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 the sample after 20,000 times was repeatedly compressed and recovered with a cycle of 1 Hz up to a thickness of 50% in a 25 ° C. 65% RH chamber with a servo pulsar manufactured by Shimadzu Corporation. The thickness (b) after standing for one day is obtained, and is calculated from the thickness (a) before treatment by the following formula, that is, ((ab) / a) × 100. Unit% (average value of n = 3)
8). Flame retardance
By F-MVSS302 method, what satisfied a flame-retardant standard (extinguishing in 60 seconds or less) was determined to be acceptable, and those not satisfying were determined to be unacceptable.
9. 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 the lethal dose (mg / 10 liter) when inhaled for 10 minutes.
10. Sitting comfort
Panelists were seated in a seat created by the method of the present invention or a seat created by a comparative method in a room at 30 ° C. and 75% RH, and the following evaluation was performed. (N = 5)
(1) Feeling with the floor: The degree of feeling when hitting the floor and “Donsun” when sitting was qualitatively evaluated. Do not feel; ◎, feel almost; ○, feel a little; △, feel; ×
(2) Feeling of stuffiness: Sitting qualitatively and qualitatively assessing the feeling of being seated for 2 hours and feeling the stuffiness of the buttock and the inner part of the hip and crotch. Almost feelless: ◎, feel slightly stuffy; ○, feel slightly stuffy; △, noticeably stuffy; ×
(3) How much patient you can sit in the seat within 8 hours: 1 hour; x 2 hours; △ 4 hours; ○ 4 hours or more;
(4) The degree of fatigue of the waist when sitting on the seat for 4 hours was qualitatively evaluated. None; ◎, almost never tired; ○, slightly tired; △, very tired; ×
(5) Comprehensive evaluation: (1) to (4) in which ◎ is 4 points, ○ is 3 points, △ is 2 points, x is 1 point and is 12 points or more and does not contain △; (◎), those with △ at 12 points or more; good (○), those with 10 points or more without x; those with slightly bad (Δ) or x; bad (×).
11. durability
In the center of the created seat (seat and back) and a flat plate with a diameter of 10 cm on the side, it can be repeatedly compressed with a compression force of 60 kg. Was determined according to the following criteria. A: No hesitation. ○: Slightly mild. Δ: There is a slight dent, the side sag comes out and you can see the sag. X: 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 / 4BD) are charged with a small amount of catalyst, and after ester exchange by a conventional method, Polytetramethylene glycol (PTMG) was added and polycondensed while raising the temperature and reduced pressure to produce a polyester ester block copolymer elastomer. Then, 2% antioxidant was added, mixed, kneaded and pelletized. Table 1 shows the formulation of the thermoplastic elastic resin raw material obtained by vacuum drying at 48 ° C for 48 hours.
[0022]
[Table 1]

[0023]
The orifice shape is a zigzag array with a width of 10 mm in the width direction and a pitch of 5 mm in the length direction on the effective surface of the nozzle having a width of 50 cm and a length of 5 cm. The existing chemical substance number (3) -3735 is used as a flame retardant while supplying the obtained A-1 and A-2 to the nozzle having a cross-section separately and quantitatively separately using an extruder having two kneading functions. Was added to a phosphorus content of 10000 ppm and melt-kneaded so that A-1 and A-2 were just before the orifice, A-1 was the seed component, and A-2 was the core component (see FIG. -S / core: 50/50 weight ratio) Distributed to the back of the orifice, discharged at 245 ° C at a discharge rate of 2.0 g / min per single hole, and discharged below the nozzle, and cooling water was placed 10 cm below the nozzle surface. , 60cm stainless endless stainless steel A pair of take-up conveyors are arranged in parallel on the surface of the water at intervals of 5 cm in parallel with each other. After sandwiching both sides, they are drawn into 25 ° C. cooling water at a rate of 1 m / min, and then drained. Table 2 shows the characteristics of the reticulate 2 obtained by cutting into a predetermined size. The network used in Example 1 is formed of a filamentous triangular cross-shaped hollow section having a seascore structure, a hollow ratio of 40%, a fineness of 9000 denier, and a phosphorus content of 10,000 ppm (60A + 200 = 2780 ppm). The average apparent density is 0.045 g / cm ³ Met. This network has a network structure that makes use of the characteristics of a soft elastic resin, so it has a cushioning function with excellent heat resistance and durability at room temperature, and is a highly safe cushioning layer that is flame retardant and has a low toxicity index for combustion gases. Met.
[0024]
[Table 2]

[0025]
95 parts of polyethylene terephthalate and 5 parts of A-1 are mixed and dried and supplied to a twin-screw extruder, while tris (2,4-di-t-butylphenyl) phosphite has a phosphorus content. An amount of 5000 ppm was added and melted and kneaded at 275 ° C., and kneaded and melted at a preheating temperature of 260 ° C. in a resin mold for the back and seat that had an opening of φ4 mm on the entire surface. The molded resin 3 obtained by injecting a thermoplastic resin and cooling and taking it out had a porosity of 36%, and the flame retardancy according to the method of item MVSS-302 was self-extinguishing.
[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 immediately before the hollow C-type orifice at 285 ° C., and an undrawn yarn is spun by a conventional method, and then drawn. After the machined fibers are subjected to mechanical crimping, solid crimps are expressed at a dry heat of 165 ° C. and cut to 51 mm, the fineness is 13 denier, the degree of crimping is 35%, and the number of crimps is 23 mountains / A base material of a fiber-fill web having a round cross section of inch and hollow ratio of 28% and having a three-dimensional winding was obtained. Using A-1 as the seed component and A-2 as the core component, discharging at 260 ° C., spinning the fiber prepared at a spinning speed of 3500 m / min into 20,000 denier, and using a crimper After applying mechanical crimping, it was cut to 51 mm to obtain a heat-bonding fiber having a fineness of 5 denier, a dry heat of 160 ° C., a shrinkage rate of 8%, and a cross-sectional shape of a solid round cross section of a sheath core. . A fiber web having a thickness of 10 mm was prepared by mixing 60 parts of the base material and 40 parts of the heat-bonding fiber by a conventional method to prepare a card web, laminating, needle punching, and cutting into a predetermined size. 11 was created.
[0027]
A-1 was melted at 240 ° C., and the basis weight was 30 g / m in a conventional manner with heated air at 280 ° C. ² 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 nets 2 and 2 'are laminated on the female mold, and the melt blown nonwoven 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 net-like body 2, and the melt blown nonwoven fabric 12 are folded back to the back side of the resin molded body 3 and hooked on the hook 9 to stop. As shown in (C), it is pressed and compressed by the male mold 10, forcedly penetrated with 200 ° C. heated air, heated for 5 minutes, maintained at that temperature for 2 minutes, and then heated air is maintained at 130 ° C. The average apparent density of the cushion layer of the seat, which was cooled and thermoformed for 10 minutes and then thermoformed by cooling, was 0.058 g / cm. ³ The average apparent density of the back cushion layer is 0.055 g / cm ³ The cushion body was obtained. Next, dimethyl terephthalic acid and 10 [2 · 3 · di (2 · hydroxyethoxy) -carbonylpropyl] 9 · 10 · dihydro · 9 · oxa · 10 phosphaphenalene · 10 oxiro are contained in an amount of 5000 ppm in phosphorus content. A 2-denier sterilized fiber prepared by copolymerizing PET obtained by adding DEG to a glycol component with a small amount of a catalyst, transesterifying by a conventional method, and polycondensating while raising the temperature and reducing the pressure. 450 g / m of fabric weight consisting of polyester fiber obtained by a conventional method using a pull ² , Air permeability 90cc / cm ² -Cover the surface of the cushion body with the side 1 of the second moquette and pull it to the back side to stop it on the resin molded body, and mold the resin with a retractable button with a recess between the side and the center The body 3 is penetrated, the side ground is suspended, and the reinforcing frame is fixed to the resin molded body. A seat as shown in FIG. 1 was prepared by backing the back or back and fixing it to a frame fixed to the vehicle. The seats obtained as shown in Table 2 had good seating comfort and durability for practical use. When the edge of the seat was exposed to a flame, the nets started to burn together with the side land and the wadding layer. In the case of using a material with good flame retardancy, this is an example in which safety can be ensured even in the event of a fire.
[0029]
Example 2
Polyester thermoplastic elasticity obtained in the same manner as in Example 1, except that 20 mol% of dimethyl isophthalate (DMI), 80 mol% of DMT and 1.4 butanediol (1.4BD) were charged with a small amount of catalyst. Table 1 shows the formulation of the resin. A characteristic of the network obtained in the same manner as in Example 1 except that a flame retardant was added to A-3 so as to have a phosphorus content of 8000 ppm, and a nozzle having a round cross section with a hole diameter of φ1 mm was used as the orifice shape. -2. In addition, it is formed from a filament having a fineness of 9000 denier and a phosphorus content of 8000 ppm (60A + 200 = 3320 ppm), and an average apparent density of the net-like body is 0.043 g / cm. ³ Met. Next, the average apparent density of the cushion layer of the seat portion prepared in the same manner as in Example 1 was 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 seat evaluation results obtained using the cushion body. As clearly shown in Table 2, the heat resistance and durability at room temperature of the mesh body are practically usable, flame retardant, and a highly safe cushioning material with a low toxicity index of combustion gas. It can be seen that it has a cushioning function with excellent sitting comfort and is durable and can be used practically. In addition, the edge of the seat was exposed to flame, but immediately extinguished.
[0030]
Example 3
Polyurethane elastomer, 4.4 'diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as chain extender are added and polymerized, then 2% antioxidant is added, mixed, kneaded, pelletized, and vacuumed Table 3 shows the formulation of the polyether-based urethane polymer after drying.
[0031]
[Table 3]

[0032]
Table 2 shows the properties of the network obtained in the same manner as in Example 1 except that a flame retardant was added so that the phosphorus content was 12000 ppm only in the obtained thermoplastic elastic resin B-1 and the melting temperature was 220 ° C. Show. In Example 3, the filaments of the mesh layer of the cushion layer were formed from the filaments having a triangular cross-shaped hollow section with a hollowness of 41%, a fineness of 9800 denier, and a phosphorus content of 12000 ppm (60A + 200 = 2480 ppm). The average apparent density is 0.045 g / cm ³ It has a cushioning function with excellent heat resistance and durability at room temperature, is a flame retardant, and has a low toxicity index of combustion gas. Then, a thermoplastic polyurethane film having a flow start temperature of 135 ° C. was used as the adhesive 12 and laminated and compressed in the same manner as in Example 1 except that the fiber-full web was not used, the thermoforming temperature was set to 172 ° C., and the annealing temperature. The average apparent density of the cushion layer of the seat was 0.060 g / cm, which was molded in the same manner as in Example 1 except that the temperature was 80 ° C. ³ The average apparent density of the back cushion layer is 0.056 g / cm ³ It can be seen that the seat of Example 3 obtained by using the cushion body is excellent in seating comfort utilizing the characteristics of soft urethane and excellent in durability for practical use. In addition, the edge of the seat was exposed to flame, but immediately extinguished.
[0033]
Comparative Example 1
Relative viscosity obtained by copolymerizing 10 [2,3, di (2, hydroxyethoxy) -carbonylpropyl] 9,10, dihydro, 9, oxa, 10 phosphaphenalene, 10 oxiro to a phosphorus content of 5000 ppm The fineness of the filament obtained in the same manner as in Example 2, except that 1.20 polybutylene terephthalate (PBT) was melted at 270 ° C., the comparative example 1 had a fineness of 8800 denier, and the phosphorus content was 5000 ppm. The phosphorus content is 5000 ppm and the apparent density is 0.044 g / cm. ³ Table 2 shows the characteristics of the network. Next, the average apparent density of the cushion layer of the seat portion prepared in the same manner as in Example 2 was set to 0.055 g / cm except that the thermoforming temperature was 250 ° C. and annealing was not performed for pseudocrystallization. ³ The average apparent density of the back cushion layer is 0.052 g / cm ³ The seat of Comparative Example 1 obtained by using the cushion body is flame retardant but sits hard because it uses a mesh body made of thermoplastic inelastic polyester with poor heat resistance and durability for the cushion layer. This is an example of a seat that is uncomfortable and has poor durability.
[0034]
Comparative Example 2
The average apparent density of the cushion of the seat portion was 0.062 g / cm using only the net-like body prepared in Example 2 without using the resin molded body and the fiber-fill web. ³ The average apparent density of the back cushion is 0.056 g / cm ³ The cushion body produced in the same manner as in Example 2 except that it was laminated and compressed so as to be thermoformed and rapidly cooled without annealing, so that the convex shape of the side portion was not used because the resin molded body was not used. The surface finish is poor, and the characteristics of the obtained seat shown in Table 2 are also examples in which the seating comfort is good, but the durability is inferior, which is not preferable. Although the edge of the seat was exposed to flame, it immediately extinguished.
[0035]
Comparative Example 3
Without using the net-like body, 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 is 0.056 g / cm ³ Table 2 shows the characteristics of the seat shown in Table 2, which was prepared by using the cushion body prepared in the same manner as in Example 2 except that it was compressed by lamination and thermoformed so that it was cooled rapidly without annealing. Although it is comfortable, it does not use a net made of a thermoplastic elastic resin excellent in heat resistance and durability.
[0036]
Comparative Example 4
Except for adding a flame retardant to A-3 so that the phosphorus content is 100 ppm, the fineness of the filament obtained in the same manner as in Example 2 is 9000 denier, the phosphorus content is 200 ppm (60A + 200 = 3320 ppm), Apparent density 0.045g / cm ³ The seat obtained in the same manner as in Example 2 except that no quasi-crystallization treatment was used, but the seating comfort was good, but the durability was slightly inferior, and the net was not sufficiently flame retardant. So when the edge of the seat was exposed to the flame, the side land and the wadding layer melted, but the flame did not drip and the flame spread and the seat burned out. This is an example of a dangerous situation in the event of a fire when a material that fails flame retardancy is used.
[0037]
Comparative Example 5
The fineness obtained in the same manner as in Example 2 was 1800 denier except that a take-up conveyor net was placed 5 cm below the nozzle surface at a discharge rate of 180 g / min and taken up at a take-up speed of 1.2 m / min. The phosphorus content is 9000 ppm (60A + 200 = 3320 ppm), the average apparent density is 0.006 g / cm ³ The apparent density of the cushion layer on the seat and back is 0.009 g / cm. ³ The seat using the cushion body obtained in the same manner as in Example 2 except that the layer compression was performed and the pseudo-crystallization treatment was not performed, and the seat was too low in density and extremely inferior in comfort and inferior in durability. It is an example.
[0038]
Comparative Example 6
The filament fineness obtained in the same manner as in Example 2 except that the discharge rate per single hole is 3 g / min, and the speed of the take-up conveyor net is 0.3 m / min. The amount is 9000ppm (60A + 200 = 3320ppm), the average apparent density is 0.21g / cm ³ The density of the cushion layer on the seat and back is 0.25 g / cm. ³ The seat obtained using the cushion body prepared in the same manner as in Example 2 except that it was laminated and compressed so as to be thermoformed and rapidly cooled without annealing, so that the cushioning layer was hard and the seating comfort was This is an example of slightly inferior durability.
[0039]
Comparative Example 7
Discharge rate per single hole of 25 g / min using a nozzle with an orifice diameter of φ2 mm arranged in a staggered arrangement with a pitch between holes in the width direction of 10 mm and a pitch between holes in the length direction of 20 mm on the nozzle effective surface having a width of 50 cm and a length of 5 cm. The fineness of the filament obtained in the same manner as in Comparative Example 2 is 113000 denier and phosphorus content, except that the wire is discharged at 1 m / min by placing a take-up conveyor net below the nozzle surface 30 cm. Is 9000 ppm (60A + 200 = 3320 ppm), and the average apparent density is 0.15 g / cm ³ The apparent density of the cushion layer on the seat and back is 0.035 g / cm. ³ The seat using the cushion body obtained in the same manner as in Example 2 except that the layer compression was performed and the quasi-crystallization treatment was not performed. This is an example of a seat that becomes less comfortable and slightly less comfortable to sit on.
[0040]
Comparative Example 8
Table 2 shows some of the characteristics of the mesh 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 placed under 60 cm of the nozzle surface. In addition, since the adhesive state is poor and the shape retention is poor, evaluation of 50% compression repulsion, apparent density, reinforcing effect, 70 ° C. residual strain, and repeated compression strain is not performed. Next, a mesh body with separated filaments is packed in a female mold, and the apparent density of the cushion layer is 0.055 g / cm. ³ The seat using the cushion body obtained in the same manner as in Example 2 except that the layered compression was not performed and the pseudo-crystallization treatment was not performed, and the comfort of the seat was poor because the filaments of the mesh body were not fused. Since the net-like shape is not fixed, the cushion material is greatly damaged and the durability is inferior.
[0041]
Comparative Example 9
Using the network obtained in Example 2, a silicone oil film was applied to the surface of the resin molded body used in Example 1, and the apparent density of the cushion layer was 0.055 g / cm without using an adhesive. ³ The seat formed using the cushion body in which the resin molded body obtained in the same manner as in Example 2 and the net-like body are not joined and integrated, except that the quasi-crystallization treatment was not performed and the layered compression was performed. The seats are not uncomfortable but have poor durability.
[0042]
【The invention's effect】
The seat of the present invention uses a mesh-like body in which filaments made of phosphorus-containing thermoplastic elastic resin having good recovery and vibration absorption are fused and integrated, and a porous resin molded body is a conventional cushion body. Since the deep-drawn molded 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 a highly safe seat that is ideal for seats, with excellent vibration isolation, heat resistance, shape retention, cushioning, stuffiness, flame retardancy, and low toxicity index of combustion gases. Moreover, in the cushion body using a conventionally known fiber-fill, deep drawing is difficult and molding is complicated, but in the method of the present invention, deep drawing can be omitted and molding can be performed in one step. Therefore, the cost of the molding process can be reduced, and a useful seat can be provided at a low cost. 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 of the present invention.
FIG. 2 is a schematic cross-sectional view of the back and seat of the seat of the present invention.
FIG. 3 is a perspective view of a resin molded body used for the back portion 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 a concept of a seat forming process of the present invention, and the process proceeds in the order of (A) → (B) → (C).
FIG. 6 is a diagram showing the concept of the seat forming process of the present invention, and the process proceeds in the order of (A) → (B) → (C).
[Explanation of symbols]
1: Side land 2: Reticulated body
3: Resin molded body 4: Opening part 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 composed of a back part and a seat part formed from a side ground, a cushion layer, and a back face deeply drawn shape part, and the injection molded resin molded body whose seat back face deeply drawn shape part has an aperture ratio of 10% or more. The resin molded body is 20 ° C. or more higher than the continuous linear melting point constituting the cushion layer, and the cushion layer has a soft segment amount (A weight%) and a phosphorus content (Bppm) of 60A + 200 ≦ B. Apparent density in which a continuous filament having a fineness of 100000 denier or less consisting of a thermoplastic elastic resin satisfying the relationship is twisted and brought into contact with each other, and most of the contact portions are fused to form a three-dimensional structure. Is composed of a reticulated body of 0.01 to 0.2 g / cm ³ , and the resin molded body and the reticulated body are composed of an adhesive or a line of the reticulated body composed of a high melting point component and a low melting point component. Composite fiber And then they are joined by self-adhesive, flame-retardant seat, characterized in that arranged flame retardancy side ground in the surface layer.

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

The flame-retardant seat according to claim 1, wherein the cross-sectional shape of the continuous filament is a hollow cross-section or an irregular cross-section.

2. The flame retardant seat according to claim 1, wherein a continuous elastic elastic component of the filament is measured by a differential scanning calorimeter and has a heat absorption peak at a temperature not lower than room temperature and not higher than the melting point.

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

The method for producing a flame-retardant seat according to claim 5, wherein a wadding layer is disposed between the cushion molded body and the side ground.