JPH0349277B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Object of the Invention (Technical Field) The present invention relates to a cushion member and a manufacturing method thereof. To be more specific, the present invention includes:
The present invention relates to a cushion member that is easy to manufacture and has good breathability and durability for use in automobile seats and the like.

(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 me 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.

The present inventors first cut synthetic fiber filaments with three-dimensional curls into predetermined dimensions, made cotton, and then compression-molded them into a predetermined shape while opening the cotton, and bonded the contact points of the filaments with adhesive. It was discovered that the cushion material has a high impact resilience, is breathable, and has excellent cushioning properties (Japanese Patent Application Laid-Open No. 152573/1983). A cushion material having a structure in which each contact point is bonded with an adhesive, and the filament of the cushion material has a partially directional curled shape and is formed by expanding and contracting. It has also been found that a filament locking material in which curled filaments are partially closely intertwined and distributed in accordance with the required load strength has an even more excellent effect. In addition, as a preforming method and manufacturing method for a cushion member made of these three-dimensionally curled filaments, 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 needle-like objects are erected. The needle-like object is brought into contact with the filament short fiber aggregate by rotating a rotating body provided therein, and preforming is performed by scraping off a predetermined portion, and the preform is compressed to a predetermined bulk density. , it is also disclosed that it is extremely advantageous to apply an adhesive liquid to the preformed body and then heat and dry the adhesive liquid (Japanese Patent Laid-Open Nos. 57-37481, 1983-1999). No. 37482).

However, although these cushion members generally exhibit good elastic performance, when used as a vehicle seat, for example, when the cushion member is placed on a spring tensioned on the seat frame, Abrasion with the spring surface destroys the intersection points of the filaments that were fixed together with the adhesive, and the durability of the cushion member on the so-called spring surface is insufficient, so as in the case of the polyurethane foam, There still remains a need to avoid direct contact and use cushioning materials such as palm lock materials, nonwoven polyethylene fabrics, and hessian cloth (plain weave) of polyethylene and polypropylene.

Furthermore, in order to solve the problem of durability of the spring surface of such a polyester filament cushion member, the present inventors compressed and formed short polyester filament fibers having three-dimensional curls of a relatively large denier into a predetermined shape. A solid material having a denier smaller than that of the filament is placed on a lower filament cushion material layer having relatively high hardness and good air permeability, which is formed by applying adhesive to the filament molded body obtained by applying an adhesive to bond the contact points between the filaments. An upper filament cushion material layer having relatively low hardness is provided by applying an adhesive to a filament molded body obtained by compression molding curled short polyester fibers into a predetermined shape to bond the mutual contact points of the filaments. We have discovered a cushion member (Patent Application No. 58-118797,
58-118798). A cushion member having this filament molded laminated structure has extremely excellent air permeability and durability.

(Problems to be Solved by the Invention) The present invention has been further researched to provide a cushion member having the filament molded laminated structure,
We have endeavored to provide a cushion member that has the same or better air permeability and durability, is easier to manufacture, and is less expensive than the filament molded laminated structure cushion member.

That is, an object of the present invention is to provide an improved cushion member and a method for manufacturing the same. Another object of the present invention is to provide a cushion member that has good breathability and durability and is easy to manufacture, and a method for manufacturing the same.

Structure of the Invention (Means for Solving the Problems) The above objects are obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape, applying an adhesive to the filament molded body, and bonding the filaments together. A filament cushion member formed by bonding contact points, characterized in that more adhesive is attached to the bottom portion of the cushion member than other portions, thereby increasing the strength of the bottom portion. Achieved by members.

The present invention also provides a cushion member in which the bottom portion of the cushion member has a bulk density of 0.02 to 0.3 g/cm ³ and the other portions have a bulk density of 0.01 to 0.2 g/cm ³ . Furthermore, the present invention provides that the polyester filament has a thickness of 50 mm as a monofilament.
2000 to 2000 denier.

The above objects further provide a filament cushion member which is obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape and applying an adhesive to connect the contact points of the filaments. In the manufacturing method, when applying adhesive to the filament molded body, consciously apply more adhesive to the bottom part of the filament molded body than to other parts, and cure the adhesive while maintaining this state. This is achieved by a method of manufacturing a cushion member characterized by the following.

The present invention also provides a method in which, when applying an adhesive to a filament molded body, the bottom part of the filament molded body is kept below in the direction of gravity, and the adhesive is moved from other parts to the bottom part by falling under its own weight. This shows a method of manufacturing a cushion member in which a large amount of adhesive is applied to the bottom surface of a filament molded body. The present invention further provides that the amount of adhesive attached to the bottom part is 50 to 500 g/100 g - filament, and the amount of adhesive attached to other parts is 10 to 300 g/100 g -
This figure shows a method of manufacturing a cushion member that is a filament.

(Function) Thus, the cushion member of the present invention is characterized in that the strength of only the bottom portion of the polyester filament cushion member is increased by using an adhesive to bond the contact points between the filaments. In other words, by applying more adhesive only to the bottom part than to other parts, the filaments near the bottom, which is the so-called spring surface, are bonded with a large amount of adhesive and a strong hardened layer is formed. Even when placed on top, it functions as an effective spring receiving material.On the other hand, other parts are no different from conventional polyester filament cushioning members, so it has good breathability, cushioning properties, etc. It has excellent performance. In addition, in this method of manufacturing a cushion member, when applying an adhesive to bond the contact points between the filaments of the filament molded body, the adhesive is intentionally applied to the bottom portion of the filament molded body in a larger amount than other parts. Furthermore, the cured layer can be obtained in the same manner as the cushion member without requiring any separate members, making it very easy and inexpensive.

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

The cushion member 1 of the present invention is made by compression-molding short polyester filament fibers having three-dimensional curls into a predetermined shape, applying an adhesive to a filament molded body to bond the contact points between the filaments, and then As shown in Figure 1, more adhesive is adhered to the bottom part of the cushion member than to other parts, forming a kind of hardened layer 2.
On the other hand, the other parts form a cushion layer 3 having good air permeability.

The polyester filament used in the cushion member of the present invention is a monofilament having a denier of 50 to 2000, preferably 100 to 1000.
The filament is a denier, most preferably 150 to 800 denier, and has three-dimensional curl. Here, the term 3-dimensional curl refers to a 3-dimensional curl in a broad sense such as a bidirectional curl or a 3-directional curl, but preferably a 3-dimensional 3-dimensional curl filament. By the disclosed method and apparatus, a double-twisted filament D as shown in FIG. 10 is made, which is then cut to a predetermined size and untwisted to obtain a three-directional three-dimensional curl filament F as shown in FIG. It will be done.
The length of the filament after cotton production is preferably 25 to 200 mm. 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, filament sections e through d are in two entanglements or coils of the helix. 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.

The bulk density of the hardened layer 2 of the cushion member 1 of the present invention is 0.02 to 0.3 g/cm ³ , preferably 0.05 to 0.2 g/cm ³
On the other hand, the bulk density of the cushion layer 3 is 0.01~
0.2 g/cm ³ , preferably 0.02 to 0.1 g/cm ³ .
The difference in bulk density between the cured layer 2 and the cushion layer ³ is due to the difference in the amount of adhesive applied. When placed, there is a risk that the durability of the bottom part where the cured layer 2 is made may be insufficient, and on the other hand, if it exceeds 0.4 g/cm ³ , there is a risk that air permeability may be inhibited. Undesirable.

In the cushion member 1 of the present invention, examples of the adhesive for bonding the contact points between the filaments include synthetic rubbers such as styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, and urethane rubber, natural rubber, vinyl-based adhesives,
Vinyl acetate adhesive, cellulose acetate adhesive,
There are acrylic adhesives, etc.

The cushion member 1 configured as described above is
It is manufactured as follows. That is, as described in JP-A No. 57-37481, for example, an aggregate of short polyester filament fibers having three-dimensional curls as described above is supplied to a conveying device, and while the conveying device is moved, a large number of needle-like objects are The filament molded body is preformed by rotating a rotary body made of an upright structure, bringing the needle-like object into contact with the filament short fiber aggregate, and scraping off a predetermined portion.
The filament molded body thus preformed is then compressed by an endless belt and/or roller or other means to form a filament molded body having a predetermined bulk density as shown in JP-A-57-211387. If necessary, this molded body is further needled with a barbed needle to achieve a predetermined needle density (or rubbed before compression molding). In this way, a filament molded body 4 having a predetermined shape as shown in FIG. 2 is molded. Next, the adhesive 6 as described above is applied to the filament molded body 4 in the form of a solution or latex by a spraying method as shown in FIG. 3a or a dipping method as shown in FIG. 3b. Note that the dipping method is preferable to the spraying method because the yield of the adhesive 6 is better and the amount of adhesive applied can be set arbitrarily. At this time, in order to apply more adhesive 6 to the bottom part 5 of the filament molded body 4 than to other parts, it is necessary to apply the adhesive liquid only to the bottom part 5 by spraying or dipping again, or to apply the adhesive liquid to the bottom part 5 of the filament molded body 4. When applying the adhesive 6,
The adhesive solution is applied by spraying or dipping while keeping the bottom part 5 downward with respect to the direction of gravity G, that is, usually with the bottom part 5 facing down, and applying an adhesive solution to other parts above the bottom part 5 more than necessary. The adhered adhesive 6 is moved to the bottom part 5 by falling under its own weight. Therefore, the amount of adhesive adhered to the bottom surface portion 5 of the filament molded body 4, that is, the portion constituting the cured layer 2, is 50 to 500 g/100 g in terms of dry weight.
The filament is preferably 80 to 400 g/100 g filament, while the amount of adhesive adhered to other parts, that is, the part constituting the cushion layer 3, is 10 to 300 g/100 g filament, preferably in terms of dry weight. 30-200g/100g-filament. Note that FIG. 8a schematically shows the adhesion state of the adhesive on the bottom surface portion, and FIG. 8b schematically shows the adhesion state of the adhesive on other portions. adhesive 6
While maintaining this state, the filament molded body 4 that has been given the adhesive is drained of the adhesive liquid as shown in FIG. 4, and is placed on the endless belt 7 running approximately horizontally as shown in FIG. Place the adhesive 5 in a drying oven 8 using hot air, infrared rays, high frequency, etc.
harden. For example, if hot air is used, 80~
200℃, preferably 100-160℃ for about 10-60 minutes,
Preferably, it is heated and dried for 15 to 40 minutes. After this,
In order to form the obtained filament cushion member 1 into a predetermined shape, it is inserted into a mold 9 and steam set as shown in FIG. Therefore, heat drying is performed again as shown in Fig. 7.

In another embodiment, after draining the adhesive liquid as shown in FIG. 4, the filament molded body 4 is placed in a mold 9 and vulcanized in a drying oven 8 as shown in FIG. 5b. A dried cushion member 1 having a desired shape can be obtained. Further, if necessary, adhesive may be applied again to the filament cushion member 1 thus completed by spraying or dipping, but in this case as well, in the same way as in the above-described process, the bottom surface portion 5 is It is necessary to apply the adhesive and heat dry it while keeping it below G.

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 ³ , 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.

In the present invention, the above adhesives can be used alone or in combination, but it is even better if the filaments are first bonded to each other with a synthetic rubber adhesive and then treated with a natural rubber adhesive. results. That is, the contact points between filaments are first bonded using a synthetic rubber adhesive that has good adhesion to synthetic fibers, and then treated with a natural rubber adhesive. The hardness of the cushion material, 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, by pre-applying a synthetic rubber adhesive, the relatively low adhesion of natural rubber adhesives to synthetic fibers is improved and increased.
At this time, the amounts of synthetic rubber latex and natural rubber latex deposited are preferably approximately the same, and the amount of synthetic rubber latex deposited is approximately the same as the amount of conventional synthetic rubber latex deposited.

The cushion member 1 of the present invention obtained as described above is used as a seat body 10 by covering necessary parts with a skin body. For example, as shown in FIG. 9, the surface portion 11 of the cushion member 1 is covered with an air-permeable skin 13 such as a fabric made of nylon, polyester, acrylic, or knitted fabric (preferably a coarse woven fabric). On the other hand, the side surface 12 and bottom surface 5a of the cushion member are made of fabric, leather,
It is covered with a skin body 14 such as artificial leather. Therefore, the air permeable skin body 13 and the skin body 14 are connected to the surface portion 11.
They are joined by sewing or other methods directly or via the beaded edge 15 at the peripheral edge. However, the cushion member 1 of the present invention does not necessarily need to be entirely covered with a skin, and there is no problem even if the cushion member 1 is used with the bottom surface portion 5a in particular exposed. Seat body 10 as above
is used by being placed on an S-shaped spring 17 or other springs, belts, etc. adjusted to the frame 16 of the seat.

Effects of the Invention As described above, the present invention involves applying an adhesive to a filament molded body obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape to bond the contact points between the filaments. The filament cushion member is characterized in that more adhesive is attached to the bottom portion of the cushion member than other portions, thereby increasing the strength of the bottom portion.
It is a cushion member that has good breathability and durability and is easy to manufacture, and is suitable for use in automobile seats and the like.

The present invention also relates to the production of a filament cushion member by applying an adhesive to a filament molded body obtained by compression molding short polyester filament fibers having three-dimensional curls into a predetermined shape to bond the contact points between the filaments. In this method, when applying adhesive to a filament molded body, the adhesive is intentionally applied to the bottom part of the filament molded body in a larger amount than other parts, and the adhesive is cured while maintaining this state. Because of these characteristics, the excellent cushion member described above can be provided extremely easily and at low cost without requiring any separate members or special steps.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of one embodiment of the cushion member of the present invention, FIGS. 2 to 7 are schematic diagrams showing each step in the method of manufacturing the cushion member of the present invention, and FIG. 8a is a cross-sectional view of an embodiment of the cushion member of the present invention. FIG. 8b is a schematic diagram showing the state of adhesive adhesion on the bottom surface of the cushion member, FIG. 8b is a schematic diagram showing the state of adhesive adhesion on other parts of the cushion member, and FIG. FIG. 10 is a cross-sectional view of the seat body used in its installed state, FIG. 10 is a partial perspective view of the double-twisted filament, and FIG. 11 is a front view of the three-dimensional three-dimensional curl filament. DESCRIPTION OF SYMBOLS 1...Cushion member, 2...Cured layer, 3...Cushion layer, 4...Filament molded body, 5...Bottom part, 6...Adhesive.

Claims (1)

[Claims] 1. A filament cushion obtained by compression-molding short polyester filament fibers having three-dimensional curls into a predetermined shape and applying an adhesive to bond the contact points between the filaments. 1. A cushion member characterized in that more adhesive is attached to the bottom portion of the cushion member than other portions, thereby increasing the strength of the bottom portion. 2 The bulk density of the bottom part of the cushion member is 0.02~
0.3g/ ^cm3 , and the bulk density of other parts is 0.01~0.2
The cushion member according to claim 1, wherein the cushioning member is g/cm ³ . 3. The cushion member according to claim 1 or 2, wherein the polyester filament has a thickness of 50 to 2000 deniers as a monofilament. 4. A method for producing a filament cushion member, in which a filament molded body obtained by compression molding polyester filament short fibers having three-dimensional curls into a predetermined shape is coated with an adhesive to bond mutual contact points of the filaments. A cushion characterized in that, when applying adhesive to a molded article, more adhesive is intentionally applied to the bottom part of the filament molded article than to other parts, and the adhesive is cured while maintaining this state. Method of manufacturing parts. 5. When applying adhesive to the filament molded body, the bottom part of the filament molded body is kept below the direction of gravity, and the adhesive is moved to the bottom part from other parts by the adhesive falling under its own weight, and the filament molding is completed. 5. The manufacturing method according to claim 4, wherein more adhesive is applied to the bottom part of the body than to other parts. 6. Claim 4 or 5, wherein the amount of adhesive adhered to the bottom part of the filament molded body is 50 to 500 g/100 g filament, and the amount of adhesive adhered to other parts is 10 to 300 g/100 g filament. The manufacturing method according to item 5.