JPH0348840B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION OBJECTS OF THE INVENTION (Field of Technology) The present invention relates to cushion members.
More specifically, the present invention relates to a cushion member used in automobile seats, etc., which has good air permeability and durability, and which can be easily and reliably attached to a support such as a seat frame.

(Prior Art) Conventionally, seats used in vehicles such as automobiles are made by using a plain weave tape made of polyethylene, polypropylene, etc., a cushion receiving material such as palm lock material, and a polyurethane foam placed on the receiving material. Mainly used is a seat body in which the surface of the polyurethane foam is covered with a skin material, and the seat body is placed on a spring stretched over a frame.
However, these seats have poor ventilation because none of the materials that make up these seats have breathability, and cannot dissipate the body heat of the occupants or the heat from the outside air. It was making people feel uncomfortable. In addition, since polyurethane foam was mainly used as the cushion material for the seat body,
If placed directly on the spring, the polyurethane foam will break at the contact surface with the spring after long-term use. For this reason,
Direct contact between the polyurethane foam and the spring is avoided, and cushioning materials such as palm lock material, nonwoven polyethylene fabric, and hessian cloth (plain weave) made of polyethylene and polypropylene are used. However, using such a cushion receiving material not only increases the cost but also reduces the cushioning properties and does not provide an air dispersion effect from the lower part. In addition, polyurethane has lower pressure elasticity than the fiber cushion material, so in order to maintain good cushioning properties, the polyurethane foam layer needs to be thicker, which overlaps with the thickness of the spring receiving material, making the entire seat higher. This had the disadvantage of making the entire car body taller.

On the other hand, as a cushion material with relatively good air permeability, a cushion member is known in which a locking material made of short synthetic fibers is integrally bonded to at least a portion of the surface of a base made of palm locking material as a sheet surface layer ( (Japanese Patent Publication No. 101164/1983). However, since the base material of such cushion materials is primarily palm lock material, they are heavy, and because they are hygroscopic, they not only pose problems in terms of reducing the weight of automobiles, etc., but also have problems in durability. In particular, when used for a long period of time, a so-called "sagging" phenomenon occurs, resulting in a decrease in the necessary cushioning properties and hardness. Moreover, there was a drawback that the desired air permeability could not be obtained.

In order to solve the above-mentioned problems with conventional products, the present inventors first developed a technique for bonding polyester filament short fibers with relatively large denier three-dimensional curls to a filament molded body obtained by compressing and forming them into a predetermined shape. Polyester short fibers having three-dimensional curls and having a denier smaller than that of the filaments are placed in a predetermined shape on a relatively hard and breathable lower filament cushion material layer formed by bonding the contact points of the filaments by applying an agent. We have found a cushion member in which an upper filament cushion material layer having relatively low hardness is formed by applying an adhesive to a filament molded body obtained by compression molding the filament to bond the mutual contact points of the filaments (patent application). (Sho 58-118797, patent application No. Sho 58-118798).
This cushion member had excellent breathability and durability, and was suitable for use in seats such as automobile seats.

Generally, in order to securely fix a vehicle cushion member to a support such as a seat frame, the ninth
As shown in Figures a and b, the cushion member 101 is provided with a flap portion 104 for attachment.
However, it has been very difficult to form a flap portion using a polyester filament short fiber aggregate having the three-dimensional curl as described above. The thickness of the flap part is 5 to 20 mm and the width is 50 to 100 mm.
This is because even if the flap part was molded in advance, it would be dragged by the mold during compression, making it almost impossible to create the desired shape.

(Problems to be Solved by the Invention) Therefore, the present invention has been made in order to solve the problems of the conventional products as described above. That is, it is an object of the present invention to provide an improved cushion member. Another object of the present invention is to provide a cushion member that has good breathability and durability and can be easily and reliably attached to the edge of a support such as a seat frame.

Structure of the Invention (Means for Solving the Problems) The above objectives are as follows:
A relatively hard polyester filament short fiber having a relatively large denier of 1500 deniers is compression molded into a predetermined shape, and an adhesive is applied to the filament molded body to bond the contact points between the filaments. Polyester filament short fibers having three-dimensional curls of 100 to 300 deniers smaller than the filament are compression-molded into a predetermined plate shape on a large lower filament cushion material layer, and an adhesive is applied to the filament molded body to bond the filaments together. A sheet-like upper filament cushion material layer having relatively low hardness is laminated, and the contact points between the filaments of the sheet-like upper filament cushion material layer and the lower filament cushion material layer are laminated. bonded by applying an adhesive, and the sheet-like upper filament cushion material layer surrounds the side surface of the lower filament cushion material layer and further protrudes below the bottom surface of the lower filament cushion material layer. This is achieved by a cushion member characterized by forming a flap portion.

(Function) Accordingly, in the cushion member of the present invention, the flap portion for fixing the cushion member, which is formed by laminating upper and lower layers of polyester filament molded bodies having different hardness to a support such as a seat frame, is attached to the upper filament member. The cushion material layer is formed into a plate shape,
A major feature is that the upper filament cushion material layer surrounds the side surface of the lower filament cushion material layer and is formed to protrude further downward than the bottom surface of the lower filament cushion material layer.
In this way, the flap portion of the cushion member can be easily and reliably formed, so that the cushion member can be easily and reliably fixed to a support such as a seat frame by means of the flap portion.

(Specific Description of the Invention) Hereinafter, the present invention will be described in more detail based on the drawings.

As shown in FIGS. 1a to 1b, the cushion member 1 of the present invention includes an upper filament cushion material layer 3 compression-molded into a predetermined plate shape and laminated on a lower filament cushion material layer 2 compression-molded into a predetermined shape. That's what happens. Thus, the plate-shaped upper filament cushion material layer 3 closely surrounds the upper surface 4 and side surface 5 of the lower filament which has been compression-molded into a predetermined shape, and its end portion protrudes downward from the bottom surface 6 of the lower filament. A flap portion 7 is formed for fixing to a support such as a seat frame.

The polyester filaments constituting the upper filament cushion material layer 3 and the lower filament cushion material layer 2 have a thickness of 100 to 300 deniers as a monofilament, preferably 100 to 200 deniers.
denier, and for the lower filament cushion material layer, its thickness is 300 to 1500 denier as a monofilament, preferably 400 to 1000 denier.
It is a denier filament with three-dimensional curls. Here, the term 3-dimensional curl refers to 3-dimensional curl in a broad sense of bidirectional and 3-directional curl, but preferably a 3-dimensional 3-dimensional curl filament,
For example, a double-twisted filament D as shown in FIG. 2 is made by the method and apparatus disclosed in Japanese Patent Application Laid-Open No. 52-144448 by the same inventor, and is then cut to a predetermined size and untwisted. A tridirectional three-dimensional curl filament F as shown in the figure is obtained. The length of filament after cotton production is 25~200mm
is preferred. Thus, portions of the filament coil in portions a over portions b, and portions c coil over portions d. However, the e section is not coiled over the f section, but below it. Thus, from e to d
The filament section is in two entwined or coiled helices. This could properly be called a non-directional helix, and is very similar to a spiral telephone cord that goes bad when one of its coils becomes non-directional with respect to the other.

Both upper and lower filament cushion material layers constituting the cushion member according to the present invention have a bulkiness of 0.04 to
0.4 g/cm ³ , preferably 0.05 to 0.2 g/cm ³ ,
Furthermore, the bulkiness of the lower layer can be made larger than that of the upper layer, but this must not result in loss of breathability. In other words, in this case, the fine denier increases the bulkiness, so even though the elasticity is high, the breathability deteriorates.In order to reduce "sagging", a highly elastic lower layer is required, so the bulkiness is increased. It is necessary to assemble a thick denier compressed body with good air permeability for the lower layer.

The cushion material is made by cutting filaments with three-dimensional curls as described above into predetermined dimensions, making them into cotton, compressing them into a predetermined shape while decompressing them, and bonding the contact points between the filaments with adhesive. It has already been discovered by the present inventors (Japanese Patent Application Laid-open No. 152573/1973) that the fibers are large, breathable, and have excellent cushioning properties. Various types of cushion materials are used in which each contact point between the filaments of the cushion material is bonded with an adhesive, and the filaments of the cushion material are formed by partially directional expansion and contraction deformation. Even more excellent is a filament locking material in which partially tightly intertwined portions of the curled filaments are formed in a direction that produces load strength, and the intertwined portions are distributed according to the required load strength. The inventors of the present invention have also previously discovered that it has a similar effect (Japanese Patent Application Laid-open No. 138662/1983). Therefore,
It is desirable that the upper filament cushion material layer 3 and the lower filament cushion material layer 2 in the present invention also have the above-described configurations.

Therefore, the cushion member of the present invention is manufactured, for example, as follows. In other words, JP-A-57-
As described in No. 37481, an aggregate of short filament fibers having three-dimensional curls is supplied to a conveying device, and while the conveying device is moved, a rotating body consisting of a large number of needle-like objects is rotated to remove the needles. The lower filament cushion material layer 2 is preformed by bringing the filament fiber into contact with the short filament fiber aggregate and scraping off a predetermined portion. On the other hand, for the upper filament cushion material layer 3, as described in JP-A No. 57-211387, an aggregate of short filament fibers having three-dimensional curls is supplied to a conveying device, and while the conveying device is moved, a large number of filament fibers are A rotating body having needle-like objects erected thereon is rotated, and the needle-like objects are brought into contact with the filament short fiber aggregate and scraped off over the entire surface, thereby forming a predetermined plate shape. The upper filament cushion material layer 3 and the lower filament cushion material layer 2 thus preformed are then respectively compressed by endless belts and/or rollers or other means as shown in JP-A-57-211387. The filament is then molded into a filament aggregate block having a predetermined bulkiness, and if necessary, this molded product is further needled with a barb-equipped needle to a predetermined needle density (or before compression molding). (rubbing). Next, after laminating each or both layers on the upper filament cushion material layer 3 and the lower filament cushion material layer 2, an adhesive liquid is applied by spraying or dipping, and after the adhesive drips, , b into a predetermined mold as shown in FIG. When placed in a mold, the upper filament cushion material layer 3 is first pressed into the lower mold 8 and compressed. Next, the lower filament cushion material layer 2 is similarly pushed into the lower die 8 and compressed with a plate 10 or the like having a predetermined shape, as shown in FIGS. 5a and 5b. Alternatively, the upper filament cushion material layer 3 and the lower filament material layer 2 may be placed in the lower mold 8 at the same time. Next, it is compressed with an upper mold 9 and heated with hot air, e.g. 80-200℃, preferably 100-160℃, for about 10-60 minutes, preferably 15-40℃.
Heat and dry for a minute and remove from the mold.

The mold used in this case is preferably made of a thin iron-based material having uniform pores, such as wire mesh, punched metal, expanded metal, or the like. For example, in the case of punched metal, the porosity should be 10 to 70%, preferably 20 to 60%, and more preferably 25 to 50%, so that heat can quickly reach the inside of the filament molded body sandwiched in the mold. It is desirable because it spreads widely. In this mold, the side parts 11 of the lower mold 8 and the upper mold 9 are either vertical as shown in FIG. 6a or wide at the top as shown in FIG. A tapered shape is desired, but a tapered shape that widens downward as shown in FIG. 6c is not desirable because the flap portion may not be formed sufficiently.

In addition, apart from the above manufacturing method, the upper filament cushion material layer 3 and the lower filament cushion material layer 2 are not placed in a mold, but individually or in a stacked state, and heated with hot air using a horizontal conveyance device such as a belt conveyor. After being vulcanized and dried using infrared rays or high frequency waves, it is pressed into a lower mold, compressed and fixed in an upper mold, set with steam, and then removed from the mold and dried using hot air, infrared rays, or high frequency waves for the required time to remove moisture. Furthermore, if necessary, an adhesive is applied by means such as spraying or dipping, and vulcanization and drying are performed.

Furthermore, when the adhesive is a moisture-curable adhesive, the adhesive is applied in the same manner as above and placed in a mold, and then heated in the presence of water vapor, for example at a vapor pressure of 0.2 to 5.
Kg/cm ² , preferably 0.5 to 3 Kg/cm ² , for a predetermined period of time, for example, 1 to 15 minutes, preferably 2 to 10 minutes, and the adhesive is cured by moisture, and after a predetermined period of time,
It is removed from the mold and dried using hot air, infrared rays, or high frequency waves to remove moisture.

Typical adhesives used for the cushion materials are synthetic rubbers such as styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, urethane rubber, natural rubber, vinyl adhesives, vinyl acetate adhesives, and cellulose acetate. There are adhesives based on acrylic and adhesives, which are used in the form of latex or solution.

In this case, the aforementioned adhesives can be used alone or in combination, but even better results are obtained if the filaments are first bonded to each other with a synthetic rubber adhesive and then treated with a natural rubber adhesive. can get. That is, by first bonding the contact points between the filaments with a synthetic rubber adhesive that has good adhesion to synthetic fibers, and then treating them with a natural rubber adhesive, The hardness of the bond, the flexibility of the cushion material as a whole, the hysteresis loss and compression set of the cushion material are improved. on the other hand,
Pre-application of a synthetic rubber adhesive improves and increases the relatively low adhesion of natural rubber adhesives to synthetic fibers. At this time, it is preferable that the amounts of synthetic rubber deluxe and natural rubber latex deposited are approximately the same, and the amount of synthetic rubber latex deposited is approximately the same as the amount of conventional synthetic rubber latex deposited. In addition, the amount of adhesive applied is usually 10 to 150
g/100g - filament, preferably 50-100
g/100g-filament.

The cushion member of the present invention obtained in the manner described above can be applied to a seat body by covering the necessary parts with a skin body.
Used as 2. For example, as shown in FIG. 7, the surface portion 13 of the cushion member 1 includes a breathable skin material 14 made of woven fabric such as nylon, polyester, acrylic, or knitted fabric (preferably coarse woven fabric).
covered with On the other hand, the side surface 1 of the cushion member
5. The flap part 7 and the bottom part 6 are covered with a skin material 16 such as fabric, leather, or artificial leather. Therefore, the breathable skin body 14 and the skin body 16
and are joined at the peripheral edge of the surface portion 13 directly or through the beaded edge portion 17 by sewing or other methods. However, the cushion member of the present invention does not necessarily need to be entirely covered with the skin, and there is no problem in using it with the bottom part 6 and flap part 7 in particular exposed as they are. The seat body 12 as described above is placed on the S-shaped spring 19 adjusted to the frame 18 of the seat or other springs, belts, etc., and fixed to the frame 18 or the S-shaped spring 19 etc. at the flap portion 7. used.

Effects of the Invention As described above, the present invention provides an adhesive for a filament molded body obtained by compression molding polyester filament short fibers having a relatively large denier three-dimensional curl of 300 to 1500 deniers into a predetermined shape as a monofilament. Polyester filament short fibers having a three-dimensional curl of 100 to 300 deniers smaller than that of the filaments are formed into a predetermined plate shape on a relatively hard lower filament cushion material layer formed by bonding the contact points of the filaments with each other. A sheet-like upper filament cushion material layer having relatively low hardness is laminated by applying an adhesive to a filament molded body obtained by compression molding to bond the mutual contact points of the filaments, and forming the sheet-like upper filament cushion. The contact points between the filaments of the material layer and the lower filament cushion material layer are bonded by applying an adhesive, and the sheet-like upper filament cushion material layer covers the side portions of the lower filament cushion material layer. Since the cushion member is characterized by forming a flap portion surrounding the lower filament cushion material layer and protruding downward from the bottom surface of the lower filament cushion material layer, it can be easily attached to a support such as a seat frame and has good ventilation. It is a cushion member with good strength and durability, and since both the upper and lower layers are composed of polyester filament molded bodies, it can be made to a desired degree of bulkiness using any denier, so it has a suitable sitting position. A comfortable product can be obtained, the filament does not dig into the S-shaped spring, etc., and it is lightweight and inexpensive. Further, since the flap portion is formed at the end of the plate-shaped filament molded body, it can be formed into any shape that matches the frame and spring shape.

[Brief explanation of drawings]

1a is a longitudinal cross-sectional view of one embodiment of the cushion member of the present invention, FIG. 1b is a cross-sectional view of the same cushion member, FIG. 2 is a partial perspective view of a double-twisted filament, and FIG. The figure is a front view of a three-dimensional three-dimensional curl filament, FIG. 4a is a longitudinal cross-sectional view of an example of a press die used for forming the cushion member of the present invention, FIG. 4b is a cross-sectional view of the same press die, and FIG. The figure is a longitudinal cross-sectional view showing how the press mold is used.
Fig. 5b is a cross-sectional view of the same state, Fig. 6a and Fig. 6
Fig. 6c is a cross-sectional view of a preferred embodiment of the press mold used for molding the cushion member of the present invention;
The figure is a cross-sectional view of an undesirable aspect of the press mold used for molding the cushion member of the present invention.
The figure is a cross-sectional view of a seat body in an attached state using one embodiment of the cushion member of the present invention, and
Figure a is a longitudinal cross-sectional view of a conventional cushion member;
FIG. 8b is a cross-sectional view of the cushion member. DESCRIPTION OF SYMBOLS 1...Cushion member, 2...Lower filament cushion material layer, 3...Upper filament cushion material layer, 7...Flap portion.

Claims (1)

[Claims] 1 As a monofilament, polyester filament short fibers having 300 to 1500 deniers and relatively large denier three-dimensional curls are compression-molded into a predetermined shape, and an adhesive is applied to the filament molded body to join the contact points between the filaments. On the lower filament cushion material layer, which has a relatively high hardness, the filament has a hardness of 100 to 300 %.
A sheet-like upper filament with relatively low hardness is obtained by compression-molding short polyester filament fibers with three-dimensional curls of denier into a predetermined plate shape, applying an adhesive to the filament molded body, and bonding the contact points between the filaments. The upper filament cushion material layer is laminated, and the contact points of the filaments of the upper filament cushion material layer in the sheet form and the lower filament cushion material layer are bonded by applying an adhesive, A cushion member characterized in that a layer of cushion material surrounds a side surface of the lower filament cushion material layer and further projects below a bottom surface of the lower filament cushion material layer to form a flap portion.