JPS6218191B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a seat cushion material and a manufacturing method thereof, and more particularly to a seat cushion material formed from a group of synthetic fiber filaments having three-dimensional curls and a manufacturing method thereof.

Conventionally, automobile seats, aircraft seats, furniture chairs, and the like do not receive a uniform load when a person sits on the seat, but usually receive a load depending on the body shape. However, cushion materials for these seats are made of fibrous materials such as straw, hemp, and elongated fibers, or combinations of these materials with springs, foam rubber,
Foam materials such as polyurethane are used, but since these are uniform materials, it is not possible to provide the desired compressive elasticity performance in a given part, and fibrous materials do not fit into the sewn spaces. Since these fibrous materials were packed together, it was impossible to mass produce cushion materials having a predetermined compressive elasticity in a predetermined portion. In other words, it has not been possible to mass-produce a single product that has the desired cushioning properties (compression elasticity) and softness in a single product or continuously.

The present inventor first created a group of filaments made of three-dimensional curl filaments of synthetic fibers with a thick denier of 30 to 1000 deniers, and then needled the required locations with a needle equipped with a barb, thereby causing the filaments to become partially entangled with each other. proposed a cushion material in which the degree of contact between the filaments is made dense and the mutual contact points of the filaments are bonded with adhesive, and a manufacturing method thereof (Japanese Patent Application No. 50934/1983).
(Refer to Publication No. 36954)), since the main purpose of such a method is to process a flat object continuously and almost uniformly, the desired cushioning properties can be achieved depending on the load applied to a specific location. The provided cushioning material was difficult to manufacture.

The present invention has been made in order to improve the various drawbacks of the conventional method as described above, and uses a cushion material in which a group of three-dimensionally curled filaments made of cotton are bonded at the contact points of the filaments with an adhesive. Depending on the magnitude of the load that the cushion material receives, (1) the bulk density of the cushion material is increased, and (2) the curled shape of the filament is partially stretched in a desired direction. This cushion material is characterized by having curled filaments of various shapes that are formed by being folded or compressed, and the degree of intertwining of the curled filaments is closely distributed.

Therefore, such a cushion material for a seat is (1)
A group of three-dimensional curl filaments made of cotton is supplied to the mold, which is formed by recessing the bottom portion of the mold corresponding to the area where the bulk density of the cushion material is to be increased, and (2) the mold is inverted. After that, remove the bottom part, (3)
The filament group supplied to the mold is compressed, and (4) the thus formed three-dimensional filament molded body is molded using a needle equipped with a barb at the tip.
The curl filaments of various shapes are poked a predetermined number of times so that the portions where the degree of partial entanglement is to be increased are densely packed, and then (5) the mutual contact points of the curl filaments constituting the molded body are bonded with adhesive. This is done by

The synthetic fibers used in the present invention include:
Examples include polyester, polyamide, polypropylene, etc., and polyester is most preferred. Its thickness is 30 to 1000 denier as a monofilament, preferably 50 to 600 denier, most preferably 100 to 1000 denier.
It is a 500 denier synthetic fiber filament with three-dimensional curls. Here, the term 3-dimensional curl refers to 3-dimensional curl in a broad sense such as bidirectional curl and tridirectional curl, but preferably a 3-dimensional curl filament.
-60297 (see Japanese Patent Publication No. 60-17856), and the length of the filament after cotton-making is preferably 40 to 200 mm, particularly preferably 60 to 150 mm.

Next, a seat cushion material and a manufacturing method thereof according to the present invention will be explained with reference to the drawings.

First, you need to organize and memorize the factors that create the desired compressive elasticity or cushioning properties, such as the thickness (denier) of the raw materials used, the size of the curl, the type and amount of adhesive, and the density of the fibers. Each mechanical device is operated by a control device connected to a computer that stores and commands conditions for producing performance, or devices that are operated and operated by a control device that incorporates predetermined conditions without using a computer. As shown in the figure.

In Fig. 1, the molding die consists of an outer peripheral wall 1 and a bottom plate 2, and the bottom part 2 has a recess into which the material can be inserted so that the molded product obtained by compression processing has the required bulk density in the required area. A sunken part 3 is formed, and a frame 5 is formed by a shaft 4 fixed to the outer peripheral wall 1.
It is rotatably mounted on the A thick denier three-dimensional curl filament 6 opened by a cotton opening machine is fed into the mold thus formed by an air blower or other means while being weighed or after weighing. In this case, one type of filament staple 6 may be used, but two or more types may be uniformly mixed or each type of staple may be supplied in a layered manner.

Then, a plate 8 of the desired shape connected to an air or hydraulic cylinder (or mechanical or electromagnetic means) 7 is lowered by actuation of the cylinder 7 to cover the filament layer 6, and the mold is reversed to form the plate 8. so that it is the bottom. In this case, the plate 8 does not necessarily have to be a flat plate, and can be provided with irregularities so as to give the molded product a desired bulk density. When inverting the mold, the cylinder 7 and the plate 8 may be made detachable, or the cylinder 7 and the plate 8 may be inverted while being connected to each other. Then, when the bottom plate 2, which has come to be located at the top, is removed by an air or hydraulic cylinder (or mechanical or electromagnetic means) (not shown), the state shown in FIG. 2 is obtained, which corresponds to the recessed part 3. The filament layer 6 bulges at the portions where it is formed.

Further, after moving the raised bottom plate 2, the filament layer 6 is compressed to a desired bulk density using a perforated plate 9 such as a perforated plate or a slit plate as shown in FIG. layer 6
Since the bulge is particularly strongly compressed, the bulk density increases accordingly. Note that this compression may be performed to achieve the dimensions and bulk density of the finished product, but as will be described later, the desired bulk density is achieved after further performing needling, locking with adhesive, etc. It may be compressed as follows. Then, when the crankshaft 10 is rotated, the crank 11
is activated, and the needle mounting plate 1 connected to this
2 moves up and down. Therefore, the filament layer is needled by vertical movement of the barbed needles 13 attached at desired intervals. As a result, the curl shape of the filament is partially stretched or compressed in an S-shape, L-shape, J-shape, 3-shape, wave shape, etc., resulting in a three-dimensional curl of the filament. intertwined with each other. The degree of intertwining, that is, the number of intertwined parts per unit area, increases depending on the spacing between the needles, that is, the density at which the needles are attached. For example, in FIG. 3, the needle density is increased to perform needling in the central portion where the bulk density is large. Necessary needle protrusion direction, needle position, number of times, etc. are determined by instructions or control by a computer, if necessary. Also,
When performing needling processing, special application
As disclosed in Japanese Patent Publication No. 109737 (see Japanese Patent Publication No. 56-22982), after inserting the tube to a predetermined depth using a barbed needle reciprocatably built into the tube with a pointed tip. Alternatively, the needle may further protrude into the filament layer to provide entangled portions of the filaments at desired locations.

The three-dimensional curled filament molded body needled in this way can be adhesively processed within the mold or after being taken out from the mold by spraying or immersing it in an adhesive and then drying it. It is done. In this case, if the molded product has a high needling density in the mold and does not lose its shape, you can apply adhesive after taking it out of the mold, but if the needling density is high enough to cause the molded product to lose its shape, use the following two methods. is used. The first is adhesives that dry relatively quickly in the mold, such as synthetic rubber adhesives such as SBR, NBR, chloroprene, and urethane rubber, polyvinyl chloride adhesives, cellulose acetate adhesives, vinyl acetate adhesives, and acrylic adhesives. After spraying into the mold using a needle-shaped sprayer with a diameter of approximately 5 to 10 mm, it dries to the extent that it adheres to the contact areas between each fiber and the molded product does not lose its shape. After applying adhesive processing, it is removed from the mold and applied with an elastic adhesive, such as an emulsion-type or solvent-type adhesive such as a polyurethane-based, natural rubber-based, or synthetic rubber-based adhesive, by spraying or dipping, The product is then completed by drying or vulcanization. The second method is to spray an elastic adhesive onto the molded product from the beginning using a needle sprayer, and then dry or vulcanize it by heating the mold or blowing hot air or steam into the mold to complete the product. . of course,
The mold referred to here requires that the surface of the mold be treated with a mold release agent or coated with a mold release agent so that it can be easily released, and the mold must also be equipped with a hook or a tool for spraying adhesive. A hole is required to insert the needle-like object, and if the processing strength is not affected, a wire mesh or a mold with many holes may be used.

Further, after the needling or adhesion processing, the plate 9 is further removed, and three-dimensional curl filament staples of different materials and physical properties (for example, denier, curl degree, etc.) are supplied and compressed, and then
Needling, adhesive processing, etc. can also be performed.

The atomizer is a double tube consisting of an outer tube 14 and an inner tube 15, both of which have pointed tips, as shown in FIG. 4, and each has at least one small hole 16, 17 near the tip. Mounting plate 18
By lowering the mounting plate 18, a needle sprayer is inserted into the molded product, and the adhesive is press-fitted from the liquid reservoir 19 and flows through the passage 20 in the outer tube 14. is sprayed from the small hole 16 when the air that is pressure-fed from the air reservoir 21 and passes through the passage 22 in the inner tube 15 is ejected from the small hole 17. In addition to using such a needle-shaped sprayer, it is of course possible to spray the molded article from above using a conventional sprayer.

The sheet cushion material obtained in this way is further heated to 80% to 80% by blowing water vapor if necessary
0.5-15 at a temperature of 110℃, preferably 90-105℃
minutes, preferably 1 to 5 minutes, to a desired compression ratio, such as 10 to 60%, preferably 20 to 40%, so that the surface is almost flat and the internal filaments as well as the degree of entanglement are compressed. A cushion material is obtained which is denser in approximately proportion to the previous one.

Note that the sheet-like cushion material according to the present invention is
Although the bulk density varies depending on the purpose of use or desired compressive elasticity, it is usually 0.005 to 0.1 g/min before adhesive treatment.
cm ³ , preferably 0.01 to 0.05 g/cm ³ , and usually 0.01 to 0.2 g/cm 3 , preferably 0.03 to 0.03 g/cm ³ after adhesive treatment.
It is 0.12g/ ^cm3 . Therefore, the final coating amount of the adhesive is usually 10 to 200 g/100 g of filament, preferably 50 to 120 g/100 g of filament, as a solid content. Furthermore, the needle density is 1
~100 pieces/100cm ² , preferably 4 to 50 pieces/100cm ² . Furthermore, it is natural that the bulk density increases by steam compression as described above.

As described above, in the seat cushion material according to the present invention, the bulk density of the cushion material is increased depending on the degree of the load that the cushion material receives, and the curl shape of the filament is partially directed in a desired direction. The filaments are formed by curl filaments of various shapes that are directionally stretched or compressed, and the degrees of entanglement are closely distributed, so that the weight of the seated person is not affected. The uniformly distributed sheet cushioning material can be provided with any ideal compressive elasticity. In addition, this cushion material does not give the feeling of bottoming out when used, unlike polyurethane foam or rubber foam, and always maintains cushioning properties like a spring, making it extremely comfortable. Furthermore, the method of the present invention includes supplying a group of three-dimensional curl filaments made of cotton to a forming die whose bottom portion corresponding to the area where the bulk density of the cushion material is to be increased is recessed. After inverting the mold, the bottom is removed and the filament group supplied to the mold is compressed, so that
Not only is a given bulk density obtained overall;
The filament, which has been raised in an amount corresponding to the size of the recessed portion, is compressed that much more, so that the bulk density of that portion is higher than that of the other portion, and this causes the cushion material to be larger in that portion. In addition, the three-dimensional filament molded body formed in this way is heated a predetermined number of times using a needle equipped with a barb at the tip so that the portions where the degree of partial entanglement of the curled filaments of various shapes is increased will be dense. Since the contact points of the curled filaments constituting the molded body are bonded with adhesive, the entanglement of the filaments can be controlled by adjusting the needling density, number of times, direction, etc., and this improves the compressive elasticity. Since the cushioning properties can be made as desired and the process is simple, the cushioning material for sheets can be mass-produced.

Next, the present invention will be explained in more detail with reference to Examples.

Example: Manufactured by the method and apparatus described in Japanese Patent Application No. 1982-60297 (see Japanese Patent Publication No. 17856-1986)
After opening a 300 denier (as a monofilament) three-directional three-dimensional curl polyester monofilament (length 80 mm), it was fed into a mold with a recessed part at the bottom using an air blower while weighing a certain amount, and then passed through a perforated plate. The mold was then inverted, the bottom portion was removed, and the filament layer was covered with a perforated plate and compressed to an average bulk density of about 0.025 g/cm ³ .
Then the average needle density is 9 needles/100cm ² (maximum 4
Needling was performed with ^{a barbed needle with a minimum of 25 pieces/100 cm 2 )} . Further, SBR latex was sprayed using a needle sprayer, and after drying, the molded body was removed from the mold and immersed in natural rubber emulsion (solid content approximately 50%), and then heated at 130℃ for 30 minutes.
By performing vulcanization for a minute, a cushion material for a sheet having a compressive elasticity distribution as shown in FIG. 5 was obtained. This product did not give a feeling of bottoming out when seated, and had extremely good cushioning properties.

[Brief explanation of the drawing]

1 to 3 are schematic cross-sectional views showing the main parts of the manufacturing process of the cushion material for sheets according to the present invention, FIG. 4 is a cross-sectional view showing an example of a needle sprayer, and FIG. FIG. 3 is a distribution diagram of compressive elasticity of a cushion material for use. 1... Outer peripheral wall, 2... Bottom, 3... Recessed part, 6
...Three-dimensional curl filament, 8,9...Plate, 1
1... Needle mounting plate, 13... Needle.

Claims (1)

[Claims] 1. In a cushion material having a structure in which a group of three-dimensional curl filaments made of cotton are bonded together at the contact points of the filaments with an adhesive, the cushion material (1) ) The bulk density of the cushion material is increased, and (2) curls of various shapes are formed by partially stretching or compressing the curl shape of the filament with directionality in a desired direction. A cushion material for sheets characterized by a densely distributed degree of intertwining of filaments. 2. The cushion material according to claim 1, wherein the three-dimensional curl filament is a monofilament made of synthetic fiber of 30 to 1000 deniers. 3. (1) Feeding a group of three-dimensional curl filaments made of cotton into a mold formed by recessing the bottom part of the mold corresponding to the area where the bulk density of the cushion material is to be increased; (2) After inverting the mold, remove the bottom part,
(3) compressing the filament group supplied to the mold; (4)
The three-dimensional filament molded body formed in this way is processed using a needle with a barb at the tip.
The curl filaments of various shapes are poked a predetermined number of times so that the portions where the degree of partial entanglement should be increased are densely packed, and then (5) the mutual contact points of the curl filaments constituting the molded body are bonded with adhesive. A method of manufacturing a cushion material for a seat, characterized by: 4. The method according to claim 3, wherein the three-dimensional curl filament is a monofilament made of synthetic fiber of 30 to 1000 deniers. 5. The method according to claim 3 or 4, wherein the bonding of curled filaments with adhesive is carried out by spraying the adhesive in a mold. 6. The method according to claim 3 or 4, wherein the bonding between the curled filaments with an adhesive is performed by immersing the curled filaments in the adhesive in a mold. 7. Bonding between curled filaments using an adhesive is carried out by spraying a quick-drying adhesive in a mold if necessary, drying it, then removing it from the mold and applying an elastic adhesive.Claim 3 The method described in any one of paragraphs 6 to 6.