JPH0334956B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to seats for vehicles such as automobiles, aircraft, furniture, etc., and more particularly to a seat sheet in which a cushion body is covered with a skin member at the same time as the cushion body is foam-molded, and a method for manufacturing the same.

Conventionally, seats have a cushion body made of foam-molded polyurethane foam covered with an outer skin.The cushion body is conventionally formed into a predetermined shape, and a polyurethane foam sheet and a backing fabric such as non-woven fabric are laminated on woven or knitted fabric, synthetic leather, etc. The outer skin is then sewn or welded, cut into a predetermined shape, and then covered with the cushion body. However, this method requires many steps such as sewing and covering, resulting in poor productivity and high costs.

For this reason, a seat sheet has been developed in which the skin is formed into a seat shape by vacuum forming and then integrally foamed with polyurethane foam. Although this method can reduce the number of steps such as covering, it is impossible to form a breathable skin, and the solution is to create a skin by bonding a non-breathable film layer to a breathable skin layer such as a woven or knitted fabric. A method has been proposed in which the member is vacuum formed and then integrally foamed together with the cushion body (Japanese Patent Publication No. 54-42297). However, even in such a seat, the seat skin surface after molding still lacks breathability, causing sweating and discomfort during use. There is also a method of forming a skin member by inserting a breathable foam layer such as polyurethane foam between a breathable skin layer and a non-breathable film layer (Japanese Patent Publication No. 48-2068); In order to vacuum form a skin member into the shape of a seat, a material with high elasticity is required, which has the disadvantage that there are restrictions on material selection and that the strength of the stretched skin member is reduced. Furthermore, there is a method in which a woven or knitted skin layer, a foam layer such as polyurethane foam, and an air-impermeable film layer are simply laminated without adhesion, and only the seat surface is covered by vacuum forming (Japanese Patent Laid-Open No. 55-121034 In the above method, the bonding strength of each layer of the skin member was not sufficient, so it could not be applied to a seat with an uneven or curved seat surface.

The present invention has been made to solve these conventional drawbacks, and involves welding appropriate parts of the laminated skin members and covering the laminated parts of the skin members at the same time as the foam molding of the cushion body. It is something.

Hereinafter, the present invention will be specifically described with reference to the accompanying drawings and the order of manufacturing steps.

First, as shown in FIG. 1, the skin member 1 used in the present invention is formed by laminating a breathable skin layer 2, a foam layer 3, and a non-breathable film layer 4, and welding them at appropriate locations. Ru. As the breathable skin layer 2, a breathable material such as woven or knitted fabric or synthetic leather is used, and
For the foam layer 3, a wadding of breathable polyurethane foam is used. Further, as the air-impermeable film layer, a sheet-like material made of a synthetic resin such as polyvinyl chloride resin, polyurethane resin, or nylon is appropriately used. The layers of this laminate are bonded together by welding, and this welding is performed using, for example, a high-frequency welding device. Second
The figure shows a state in which this high-frequency welding is performed, in which the laminate 1 is sandwiched between a lower electrode 11 and an upper electrode 12 of a high-frequency welding device, and by energizing the electrodes 11 and 12, the laminated body 1 is separated at appropriate intervals. Welded parts 5, 5, . In this case, the lowermost breathable skin layer 3 has a foam layer 3 and a non-breathable film layer 4 at the left and right ends.
Although it extends laterally than the extending portion 2a,
Reference numeral 2a covers a portion of the cushion body other than the seat surface. Note that the other layers 3 and 4 may be laminated and welded on this extension. In Figure 2, 6,
Reference numeral 6 denotes a bead formed on the welded portion by buttons, stitching, etc., and is intended to improve the strength of the welded portion.

The skin member 1 thus formed is then placed in a vacuum forming mold for foam-molding a cushion body, as shown in FIG. In the same figure, 1
3 is a lower mold in the vacuum forming diagram, 14 is a middle mold, and the skin member 1 is placed on the upper surface of this lower mold 13 with the breathable skin layer 2 in contact with the lower mold 13 and the middle mold 14 on both sides. Temporary fixing is performed by applying pressure to the Here, it is preferable to set the welded portion 5 or bead 6 so that it is located at a location where the skin member 1 is bent, since it is possible to suppress the expansion of the skin member 1. A vacuum chamber 15 is provided in the lower mold 13.
is formed, and a plurality of suction holes 16, 16, . becomes. On the other hand, since the non-breathable film is integrated with the skin member 1 by welding, from the middle mold 14 to the lower mold 13
Therefore, when the lower mold 13 is depressurized, the skin member 1 comes into close contact with the upper surface of the lower mold 13, as shown in FIG. It is curved into the shape of. In this state, a foaming solution of polyurethane resin is injected from the nozzle 18 above the skin member 1, and while the vacuum chamber 15 is suctioned and the lower mold 13 is maintained in a reduced pressure state, the upper mold 19 is covered as shown in FIG. Then, the cushion body 7 is foam-molded. By this foaming, the skin member 1 and the cushion body 7 are integrated, and a seat as shown in FIG. 6 is obtained. In this seat, the skin member 1 in the laminated state covers the seat surface that comes into contact with the body of the seated person, and the breathable skin layer 2 of the skin member 1 is the uppermost layer, and the breathable foam layer is the middle layer. Since the seats are located at the top and bottom, the breathability of the sheet is good.

Note that extending portions 2 extending to both sides of the skin member 1
a, 2a are high-frequency welded to the sides of the cushion body 7;
By joining by adhesion, suturing, etc., the side portions can be easily covered. In such molding, the laminated portion of the skin member is curved along the mold. However, since this laminated part has unevenness due to the presence of the welded part 5, it cannot be deep drawn like when a flat skin is curved into a seat shape.
There is no need for large extensibility in the breathable skin layer or film layer, so there are no restrictions on material selection, and there is no decrease in strength due to stretching.

7 to 9 show a method of covering not only the seat surface of the cushion body but also the side portions of the cushion body with the laminated skin member. In this method, as shown in FIG. 7, both ends of the skin member 1 set in the vacuum forming mold are erected along the middle mold 14 and locked onto the upper part of the middle mold 14 by the presser parts 20. In this state, the lower mold 13 is depressurized. In this case, since both sides of the skin member 1 located on the sides of the cushion body 7 do not particularly require air permeability, the air permeable skin layer 2 and the non-breathable film layer are welded together without laminating the foam layer. However, in any case, since there is no air leakage from the skin member 1, the skin member 1 is separated by the lower mold 13 and the middle mold 14 by reducing the pressure of the lower mold.
It curves along and fits tightly onto the top surface of these. Therefore, by injecting the foaming stock solution through the nozzle 18 and foaming, the cushion body 7 and the skin member 1 are integrated, and the seat sheet shown in FIG. 9 is formed. 1st
Figure 0 shows another example of this molding, in which the skin member 1
The bead 6 is located at the bending point, and the extension at the bending point is effectively suppressed.

According to the present invention described above, the laminated portion of the skin member (welded at multiple appropriate locations) is integrally foamed and molded with the cushion body.
Even if it is curved to follow the shape of the seat, deep drawing will not occur and the breathable skin layer and non-breathable film layer will not be stretched more than necessary, so there will be no strength loss due to stretching, and it can be used for the above two layers. There are no restrictions on the material.

[Brief explanation of drawings]

Fig. 1 is a sectional view of the skin member in a laminated state, Fig. 2 is a sectional view showing the welded state, Figs. 7 and 8 are cross-sectional views of another manufacturing example, and FIG. 9 is a cross-sectional view of the seat.
Figure 0 is a sectional view of another example of the seat. 1...Skin member, 2...Breathable skin layer, 3...
...Foam layer, 4...Non-breathable film layer, 5...
Welding part, 7...Cushion body, 13...Lower mold, 1
9... Upper mold.

Claims (1)

[Scope of Claims] 1. A skin member in which a breathable skin layer, a foam layer, and a non-breathable film layer are laminated is welded at a plurality of appropriate locations, and the laminated portion of this skin member is made of polyurethane foam. A seat sheet characterized by being covered with an integrally foamed cushion body. 2 After laminating the breathable skin layer, the foam layer, and the non-breathable film layer, a skin member is formed by welding at multiple appropriate locations, and the breathable skin layer of the laminated portion of this skin member is used for vacuum forming. A seat sheet characterized in that the seat sheet is placed in contact with a lower mold, the lower mold is depressurized to bring the skin member into close contact with the lower mold, and then a foaming solution is injected from above the skin member to perform foam molding. manufacturing method.