JPH0342572B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention involves forming an integral molded article, specifically a heat-formable nonwoven fiber web (hereinafter referred to as web) into a fiber cushion body (hereinafter referred to as cushion body), and at the same time adhering the skin. The present invention relates to an integrally molded body.

Conventionally, urethane foams have been mainly used as cushion bodies, but urethane foams change over time due to moisture and heat deterioration, so they must be manufactured with a hard texture. There were disadvantages such as feeling depressed, feeling like you had hit rock bottom, and being disliked.

The present inventors previously identified and proposed a polyester fiber cushion material that eliminates these drawbacks and exhibits excellent performance while eliminating these drawbacks in Japanese Patent Application Laid-Open No. 58-31150. We conducted research to produce seats suitable for vehicles and general furniture at low cost by simultaneously performing thermoforming and adhesion of the skin.

Conventionally, seat bodies have been very labor-intensive, so a vacuum forming method has been provided in which urethane or the like is foamed in a bag-shaped skin to form a cushion body. This method has the following disadvantages: (1) a breathable skin cannot be used; and (2) it is difficult to repair large spaces inside the urethane or between the skin and the urethane.

In recent years, there has been an increasing demand for sheet breathability, a soft feel for the skin, a luxurious feel, etc., and products and manufacturing methods that meet these demands have been proposed.

Namely, Japanese Patent Publication No. 17087, Japanese Patent Publication No. 1983-17087,
This method is disclosed in Japanese Patent Application Laid-open No. 17087 and Japanese Patent Application Laid-open No. 56-63388, etc., in which wading, molding, etc. made of urethane foam are sequentially adhered to the skin of a bag-shaped fabric. However, although this method satisfies the breathability of the seat body and the good feeling of the surface, and does not cause a deterioration in quality, it is time-consuming.

An object of the present invention is to eliminate such drawbacks and provide an integrally molded body that has breathability, soft feel, and a luxurious feel without causing quality deterioration, and which can be manufactured at low cost and is suitable for seat bodies, etc. Of course, it can also be used as a wall covering, a sound absorbing material, etc., or as a part of a seat body.

The object of the present invention is to provide heat-adhesive fibers with a low melting point.
10 to 50% by weight of the thermoadhesive fibers and 90 to 50% by weight of synthetic fibers and/or non-thermally adhesive fibers having a higher melting point than the thermoadhesive fibers, or a laminate thereof, with the thermally adhesive fibers on at least one side. The outer skin is layered with a sheet containing at least 40% by weight, and by applying pressure and heating, at least a portion of the intertwined portions of synthetic fibers and/or non-thermal adhesive fibers in the web are bonded together, and the web is This is achieved by an integrally molded body formed by adhering and integrally molding the above-mentioned skin.

The synthetic fibers and non-thermal adhesive fibers used in the present invention include various known fibers, such as synthetic fibers such as polyester, polypropylene, and polyacrylic; natural fibers such as cotton, wool, and hemp; and recycled fibers such as rayon and Kyupra. Synthetic fibers such as polyester and polypropylene are preferable, but synthetic fibers such as polyester and polypropylene are preferable.
More preferably, polyester fibers are used because of their excellent performance. As polyester,
Examples include ordinary polyethylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly1,4-dimethylcyclohexane terephthalate, boribivalolactone, or composite fibers made by copolyesters or conjugate spinning of these, but polyethylene terephthalate is most suitable. The cross-sectional shape may be circular, irregularly shaped, or hollow. In addition, the fineness is usually 1 to 50 deniers, and the fiber length is usually 30.
~150m/m is sufficient.

The heat-adhesive fiber may be any material as long as it has a melting point lower than that of the non-thermally-adhesive fiber, preferably 30°C or lower, has adhesive properties, and exhibits a fiber morphology, but preferably copolyester, Examples include polyolefin, polyvinyl alcohol, and more preferably copolyester.

Examples of polyesters include aromatic dicarboxylic acids such as adipic acid, sebacic acid, and naphthalene dicarboxylic acid, and/or alicyclic dicarboxylic acids such as hexahydroterephthalic acid and hexahydroisophthalic acid, diethylene glycol, polyethylene glycol, propylene glycol, and paraxyl ring. It is a copolyester containing a predetermined number of aliphatic or alicyclic diols such as Recall, and optionally oxyacids such as parahydroxybenzoic acid. For example, isophthalic acid is added to terephthalic acid and ethylene glycol. and conjugate fibers made by copolymerizing 1,6-hexanediol and by conjugate spinning.
In addition, the fineness is usually 1 to 20 denier, and the fiber length is usually
It is sufficient if it is 30 to 100m/m.

The web of the present invention is preferably 10 to 50% by weight.
15 to 30% by weight of thermally bondable fibers and 90 to 50% by weight, preferably 85 to 70% by weight of synthetic fibers and/or non-thermally bondable fibers having a higher melting point than the thermally bondable fibers are mixed, and a known Formed by Weber. In a mixed web of heat-adhesive fibers and non-thermally-adhesive fibers, if the ratio of heat-adhesive fibers is less than 10% by weight, the heat fusion between the fibers of the produced cushion body will be insufficient; %, there will be too much fusion and it will become too hard. By appropriately changing the mixing ratio of both fibers within this range, the hardness of the cushion body can be changed. Further, by varying the mixing ratio of the web layer, it is possible to obtain a cushion body with partially different hardness. Furthermore, it is also possible to use a web that has been partially preformed by applying pressure and heating.

The density of the web or its laminate is 0.005~
When adjusted to 0.15 g/cm ³ , the molded cushion body exhibits a suitable impact resilience.

There is at least 40% polymerization between the web and the epidermis, preferably at least 70% by weight, particularly preferably approximately
A sheet containing 100% by weight of heat-adhesive fibers is interposed, and the cushion body and the skin are bonded together by pressing and heating. If the content of the heat-adhesive fiber is less than 40% by weight, the adhesion between the cushion body and the skin will not be sufficient. By setting the ratio within this range, the cushion body and the outer skin are bonded at points, and the soft feel of the outer skin can be utilized.
Also, the sheet referred to herein includes a thin web.

The skin of the present invention may be of any material, such as paper, nonwoven fabric, natural leather, knitted fabric, etc., as long as it exhibits adhesion to heat-adhesive fibers, either directly or through some kind of third layer, but is breathable, A knitted fabric with a soft feel is suitable, and a polyester knitted fabric with stretchability is particularly suitable. However, depending on the application, a non-breathable skin such as vinyl chloride leather may be suitably used.

The skin may be used as it is, but if it is to be adhered to at least three sides of the web, it is preferable to use a skin whose external shape has been previously formed by a known method. Particularly in the case of five-sided bonding, it is preferable to form the skin into a bag shape in advance. In addition, when performing embossing, the shape may be created on the skin using an upper mold and a lower mold that can be heated in advance, but it is also possible to process a pre-integrated molded body using a mold that can be heated. It is.

The molding of the cushion body of the present invention and the adhesion of the skin are carried out by sequentially laminating and pressing the web, sheet, and skin between parallel plates or within a mold, and heating this with moist heat means such as hot water, steam, or high-pressure steam. ,
The heating means may be dry heat means such as hot air.
Furthermore, it is also possible to continuously form and bond between endless belts.

The integrally molded article of the present invention produced in this way is suitable as a seat body having the excellent performance of the cushion body, the breathability of the skin, a soft feel, and a luxurious feel.

Next, the present invention will be explained with reference to the drawings.

FIG. 1 shows, in cross section, the structure of an example of the integrally molded body of the present invention.

1 is a cushion body, 2 is a sheet, 3 is an outer skin 4 is a calyx portion, and 5 is an embossed groove portion.

Although not shown, in the cushion body of the present invention, a large number of fibers are irregularly intertwined in three dimensions, and all or the heat-adhesive portions are fixed by knots made by melting. Although it is a thing,
The impact resilience of synthetic fibers or non-thermally adhesive fibers is less likely to be diminished.

In addition, since the skin is bonded by the heat-adhesive fibers that make up the sheet, it becomes point bonding, and even when the material is soft to the touch, this feel can be utilized.

As shown in the perspective view of Figure 2, the adhesion of the epidermis is 3.
It can be suitably taken from one surface of only a to vertical surfaces of 3a, 3b (including opposing surfaces not shown), and 3c (same as 3b).

The calf portion and the embossed groove portion shown in FIG. 1 may be omitted.

Although not shown, it is also possible to use the cushion body as a portion corresponding to the wadding and the skin.

FIG. 3 shows a cross-sectional view of an example in which the skin is formed into a bag shape and embossed in advance.

The bag-like formation may be performed using a known method such as sewing by a sewing machine or high-frequency welding. Further, the embossing may be formed by heating and pressing between heated upper and lower molds. Although not shown, the beading may or may not be formed.

FIG. 4 shows an example using cushion bodies having different hardnesses.

For example, it is also possible to preform the part of the cushion body indicated by 1b and use it.

Next, the present invention will be explained with reference to examples.

Example 1 Polyethylene terephthalate/copolymerized polyester (terephthalic acid/isophthalic acid = 60.40, melting point 110°C), core-sheath type, composite fiber (fineness 4 denier, fiber length 51 m/m) was used as the thermal adhesive fiber. Polyethylene terephthalate fiber (melting point 257
℃, fineness 10 denier, fiber length 51 m/m) is used. Polyethylene terephthalate fibers and copolyester fibers were mixed at a ratio of 80:20, and a web with a basis weight of 200 g/m ² was produced using a random webber.

In addition, after producing a web with a basis weight of 40 g/m ² using a roller card using copolyester polyester fiber (fineness 0 denier, fiber length 51 m/m) alone, by passing it between rollers (140°C 40 Kg/cm ² G) , a heat-pressure bonded sheet is produced in advance.

On the other hand, a tricot-raised polyester product for automobile seats was machine sewn into the shape of the seat cushion of a front seat, and embossed with an upper mold and a lower mold that can be heated with steam to obtain a bag-shaped skin.

Next, the bag-shaped skin was transferred to a stainless steel mold having punched holes of approximately the same shape as the lower mold, the sheet was placed therein, and the web was placed on top of the mold with a density of 0.03.
The molds were stacked and filled to a density of g/cm ³ , and the mold was covered with a top lid with punched holes, and then placed in a double high-pressure can.
After reducing the pressure inside this can to 50mmHg, we used high-pressure steam at 130°C to form the cushion body and adhere the skin.
Do this for 10 minutes. After releasing the high-pressure steam to atmospheric pressure, the pressure inside the can is reduced to 50 mmHg again to sufficiently reduce the adhering moisture. Next, after introducing air into the can and returning it to atmospheric pressure, the mold is removed from the can.
Take out the integral molded body from the mold.

The obtained integrally molded product exhibited excellent impact resilience and was suitable for use as a seat body having breathability, a soft feel, and a luxurious feel.

Example 2 A web and a sheet are manufactured in the same manner as in Example 1.

A bag-shaped skin obtained by sewing a tricot brushed polyester product for automobile seats into the shape of the seat cushion part of a front seat is placed in a stainless steel mold having punched holes of approximately the same shape, and the web and seat are An integral molded body was produced in the same manner as in Example 1.

Next, the integral molded body is placed in a stainless steel mold having an embossed convex mold, and the mold is covered with a top, and then
Emboss formation was performed under the same conditions as when making an integrally molded body.

The integral molded body embossed in this way was a molded body suitable for a seat body, as in Example 1.

Example 3 In the same manner as in Example 2, an integral molded body is manufactured. Next, an embossed convex mold that can be heated with steam is heated to 130° C., and the convex mold is pressed against the above-mentioned integral molded body for 3 minutes. Next, after releasing the heated steam in the convex shape to the atmosphere,
At the same time as reducing the pressure to mmHg, the vicinity of the convex pressing portion is cooled by blowing cold air. After cooling to 70° C. or below, the pressed convex mold is raised and the integral molded body is removed.

The integral molded body embossed in this manner was suitable for use as a seat body, as in Example 1.

Example 4 Similar to Example 1, polyethylene terephthalate fibers and copolymer-containing polyester fibers were mixed and processed to a fabric weight of 400 using a roller card and a cross wrapper.
A web of g/m ² is produced.

The web, sheet, and skin were layered and passed in this order between endless driving belts made of gold and steel with a vertical interval of 20 m/m, and heated with hot air at 180° C. for 5 minutes. The sheet referred to here is the one shown in Example 1, and the skin is the same as in Example 1 before being processed into a bag.

The obtained integrally molded body was suitable as a wadding with a skin for a seat body.

Comparative Examples 1 to 3 Although various integrally molded bodies were manufactured as shown in Table 1, sufficient performance could not be obtained for the reasons shown in the evaluation section.

■■■ Turtle shell [0002] ■■■ Example 5 A web and a sheet are manufactured in the same manner as in Example 1.

Smooth polyester lining for motorcycle seats Adhesive vinyl chloride leather is sewn into a double seat shape using a high-frequency welder.

Next, an integral molded body is produced in the same manner as in Example 1 except that the temperature of the high-humidity steam is 115°C.

The obtained integrally molded product exhibited excellent impact resilience and was suitable for use as a double seat for two-wheeled vehicles.

Example 6 The skin was made of polyester smooth lining for motorcycles, adhesive chloride beer leather was heated with hot air at 160°C for 10 days.
An integrally molded body is manufactured in the same manner as in Example 4 except that the heating time is set for 1 minute.

The obtained integral molded product was suitable as a wadding with a skin for a double seat for a two-wheeled vehicle.

Example 7 Polypropylene/polyethylene parallel composite fibers (melting point 165°C/130°C, fineness 6) were used as thermally adhesive fibers.
An integrally molded body is manufactured in the same manner as in Example 1, except that a sheet is manufactured using the composite fiber (denier fiber length: 64 m/m) and the sheet is manufactured using the composite fiber.

The obtained integrally molded body, like Example 1, was a molded body suitable for a seat body.

Example 8 An integral molded body is produced in the same manner as in Example 5, except that polypropylene/polyethylene parallel conjugate fibers are used as in Example 7, and a sheet is produced using the conjugate fibers.

As in Example 5, the obtained integrally molded body was a molded body suitable for a double seat for a two-wheeled vehicle.

[Brief explanation of drawings]

Figure 1 is a cross-sectional view of the integral molded body, Figure 2 is a perspective view of the integral molded body, Figure 3 is a cross-sectional view of the skin sewn into a bag shape and embossed, and Figure 4 is a cushion with different hardness. FIG.

Claims (1)

[Claims] 1. 10 to 50% by weight of thermally adhesive fibers having a low melting point
and 90 to 50% by weight of synthetic fibers and/or non-thermally adhesive fibers having a higher melting point than the thermally adhesive fibers, or at least 40% by weight of the thermally adhesive fibers on at least one side of the web or laminate thereof. Layering the outer skin through the containing sheet and applying pressure and heating to bond at least a portion of the intertwined portions of synthetic fibers and/or non-thermal adhesive fibers in the web, and bonding and integrally forming the web and the outer skin. An integrally molded body. 2. The molded article according to claim 1, wherein the web contains 15 to 30% by weight of heat-adhesive fibers. 3. The molded article according to claim 1 or 2, wherein the heat-adhesive fiber is a polyester fiber. 4. The molded article according to claim 3, wherein the polyester is a copolymerized polyester. 5. The molded article according to claim 1, wherein the synthetic fiber is a polyester fiber. 6 The content of thermal adhesive fiber in the sheet is 70% by weight
The molded article according to claim 1, which is the above. 7. The molded article according to claim 1, wherein the skin is a knitted fabric. 8. The molded article according to claim 1 or 7, wherein the outer skin is a stretchable polyester fiber knitted fabric. 9. The molded article according to claim 1, wherein the skin is synthetic leather. 10. The molded article according to claim 9, wherein the synthetic leather is made of vinyl chloride. 11. The molded article according to claim 1, wherein the skin is adhered to at least three sides of the web or a laminate thereof. 12 Claim 1 in which the skin is made into a bag in advance
The molded article described in Section 1. 13. The molded article according to claim 1, wherein the skin is pre-embossed. 14. The molded article according to claim 1, wherein a part of the web is preformed by applying pressure and heating. 15 The density of the web or its laminate is 0.005~
The molded article according to claim 1, which has a weight of 0.15 g/cm ³ .