JPH02258332A - Reinforced material base cloth for foam molding - Google Patents

Abstract

PURPOSE:To prevent an air vent from getting blocked, carry out uniform foam molding and increase surface rigidity by using a non-woven cloth with specified weight per unit area and specified diameter. CONSTITUTION:A reinforced material base cloth 1 for foam molding constituted of a non-woven cloth 2 of high weight per unit area, having 110 - 800g/m<2> per unit area and 1 - 16d fiber diameter is used. Such a non-woven cloth never prevents air from passing through at the time of foam molding and also prevents resin liquid from passing through and prevents an air vent from getting blocked, and absorbs resin liquid to provide proper rigidity to a foam molded product. Rigidity can further be increased by forming a pressure welded layer 3 on one surface of the non-woven cloth 2.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a reinforcing material base fabric for foam molding of foam molded products such as foamed polyurethane used for vehicle seats and the like.

[Conventional technology]

Foamed products such as soft polyurethane foam are used as cushioning materials for vehicle seats.

When used as a cushioning material for vehicle seats, etc., the bottom part is designed to effectively receive the pressing force of the coil springs attached to the bottom of the cushioning material, so that it will not be damaged, and also to provide rigidity and tension to the cushioning properties. Reinforcements are installed.

Conventionally, cheesecloth and slab urethane are used as such reinforcing materials, and when performing one-foam molding, a slab urethane is placed in contact with the mold surface of a foaming pot that has a mold surface that has the same shape as the molded product, and cheesecloth is placed inside of the slab urethane. A urethane solution is injected into the foam, which is heated and pressurized to form foam. In this case, the cheesecloth functions as a reinforcing material, but the slab urethane also provides rigidity and prevents the air vent holes of the foam kettle from being blocked. However, there are problems in that using only such cheesecloth and slab urethane lacks rigidity, requires filling with wire, and requires complicated work.

In order to improve these points, the basis weight is 10~30g/d.
A reinforcing material base fabric for urethane foam molding of vehicle seats has been proposed, which is made of a nonwoven fabric that integrates a thin, dense layer with a fabric weight of 40 to 100 g/n (200 g/n) and a coarse, bulky layer with a fabric weight of 40 to 100 g/n. 26193), however, integrating these two layers of nonwoven fabric requires complicated work, and simply integrating the two layers does not prevent the air vent hole from clogging due to the passage of the urethane liquid. In addition, if an adhesive layer is formed between the two layers to block the passage of the urethane liquid, the passage of air will also be blocked, and the urethane liquid will not penetrate into the nonwoven fabric, resulting in an inferior function as a reinforcing material. There was a problem.

[Problem to be solved by the invention]

The purpose of the present invention is to solve the above-mentioned problems.
Foam molding that prevents the passage of resin liquid and prevents clogging of air vent holes without blocking the passage of air during foam molding, and that can absorb the resin liquid and impart appropriate rigidity to the foam molded product. An object of the present invention is to provide a reinforcing material base fabric for use in the present invention.

[Means to solve the problem]

The present invention is the following reinforcing material base fabric for foam molding.

(1) Fabric weight 110-800g/m2, fiber diameter 1-16d
A reinforcing material base fabric for foam molding, characterized by being made of a nonwoven fabric with a high basis weight.

(2) Fabric weight 110-800g/rrr, fiber diameter 1-16
A reinforcing material base fabric for foam molding, characterized in that it is made of a nonwoven fabric with a high basis weight and has a pressure bonding layer on one side.

The material to be foam-molded in the present invention is a foamable material that forms foam molded products used for vehicle seats and other uses, and includes foamable resin liquids such as urethane liquids that form foamed polyurethane foam. , but not limited to.

The fibers constituting the high basis weight nonwoven fabric used in the reinforcing material base fabric of the present invention can be made of any material such as polyamide (nylon), polyester, polypropylene, etc.
Thermoplastics are preferred.

Moreover, any form of fiber can be used, such as long fibers, short fibers, or a combination thereof.

The reinforcing material base fabric of the present invention is formed from these fibers and has a basis weight of 110 to 800 g/rrr, preferably 200 to 40 g/rrr.
0g/i and fiber diameter 1-16d, preferably 8-15
It is a high weight nonwoven fabric of d. Such a high basis weight nonwoven fabric can be used as it is as a reinforcing material base fabric.

It is preferable that a pressure bonding layer is formed on one side of such a high basis weight nonwoven fabric, that is, the side opposite to the side through which the foamable resin liquid such as urethane liquid permeates.

〔Example〕

EMBODIMENT OF THE INVENTION The present invention will be explained below with reference to embodiments shown in the drawings.

FIG. 1 is a cross-sectional view of the reinforcing material base fabric when a pressure bonding layer is formed, and FIG. 2 is a cross-sectional view of the reinforcing material base fabric when a pressure bonding layer is not formed.
) shows the state before foam molding, and (B) shows the state after foam molding, 1 is the reinforcing material base fabric, and in FIG. There is, but the second
In the figure, it consists of a uniform layer of a high basis weight nonwoven fabric 2, and no pressure bonding layer 3 is formed.

The pressure bonding layer 3 shown in FIG. 1 can be formed by embossing or mirroring one surface of the uniform nonwoven fabric 2 with a high basis weight as shown in FIG.

For single-sided embossing or mirror processing, in the case of a nonwoven fabric made of thermoplastic fibers, it is compressed by passing it through the high density nonwoven fabric 2 shown in Fig. 2 between a high temperature embossing roll or mirror processing roll and a low temperature ordinary roll. It is formed by thermocompression bonding. In the case of a nonwoven fabric made of non-thermoplastic fibers, the pressure bonding layer 3 can be formed by impregnating one side with an adhesive and performing embossing or mirror processing.

The above-mentioned reinforcing material base fabric 1 is formed by foam molding by impregnating one side of the nonwoven fabric 2, which is the side on which the pressure bonding layer 3 is not formed in FIG. 1, with a foaming resin liquid such as urethane liquid in the X and Y directions. 0 Foam molding is performed by installing the reinforcing material base fabric 1 on one side of the reinforcing material base fabric 1, which is the pressure bonding layer 3 in FIG. A liquid is introduced and impregnated into the reinforcing material base fabric 1, and foamed under heat and pressure to form a single foamed molded article 7.

At this time, the air in the cavity 6 is discharged from the air vent hole through the base fabric l, but since the base fabric 1 has a high basis weight, the resin liquid impregnated layer 8 is crimped in the middle of the base fabric 1, in the case of Fig. 1. layer 3
The impregnated layer 8 increases the surface rigidity of the foam molded product 7, and when used as a cushion material for automobile seats, it does not pass through the base fabric 1 and block the air vent hole. It supports pressure effectively and will not be damaged.

In the above description, foam molding using a reinforcing material base fabric is suitable for foam molding of automobile seats, but it is suitable for foam molding of automobile seats, furniture,
It can also be applied to molding foam molded products for other uses such as office chairs.

〔Effect of the invention〕

According to the present invention, by using a high basis weight nonwoven fabric, there is no clogging of air vent holes, uniform foam molding is performed, and
Surface rigidity can be improved.

In addition, by forming a pressure bonding layer on one side of the high-date nonwoven fabric, the impregnation of the resin liquid is stopped in the middle of the base fabric, the degree of resin liquid impregnation is adjusted, and a dense foam layer is formed to further improve rigidity. be able to. By combining these, it is possible to perform foam molding with different hardness depending on the location. In addition, according to the present invention, the Il manufacturing process can be simplified and the number of wires used for imparting rigidity can be reduced.

[Brief explanation of drawings]

The drawings show examples, and FIG. 1 shows the case where a pressure bonding layer is formed.
FIG. 2 is a sectional view of the reinforcing material base fabric when no pressure bonding layer is formed, and (^) shows the state before foam molding, and (B) shows the state after foam molding. In each figure, the same reference numerals indicate the same or equivalent parts, 1 is the reinforcing material base fabric, 2 is the high basis weight nonwoven fabric, 3 is the pressure bonding layer, 4.5 is the mold surface, 7 is the foam molded product, and 8 is the impregnated layer. be. Agent Patent Attorney Sei Yanagihara

Claims (2)

[Claims] (1) Fabric weight 110-800g/m^2, fiber diameter 1-16
A reinforcing material base fabric for foam molding, characterized in that it is made of a high basis weight nonwoven fabric of d. (2) Fabric weight 110-800g/m^2, fiber diameter 1-16
A reinforcing material base fabric for foam molding, characterized in that it is made of a nonwoven fabric with a high basis weight and has a pressure bonding layer on one side.