JP2005177198A - Seat pad - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the generation of abnormal noise due to scratching noise with a support frame in a seat pad.
SOLUTION: A sheet pad 10 comprising a pad main body 12 made of polyurethane foam and a reinforcing material 14 integrated on the back surface thereof by foam molding of polyurethane foam, wherein the reinforcing material 14 is a woven fabric layer made of woven fabric. 20 and a nonwoven fabric layer 22 made of short fibers of 1 to 5 dtex are laminated and integrated by needle punching, and integrated with the pad body 12 with the fabric layer 20 side as the pad body 12 side.
[Selection] Figure 2

Description

  The present invention relates to a seat pad used as a seat cushion material for a vehicle or the like.

  In general, a seat pad used as a seat cushion material for a vehicle or the like is made of a molded product of a soft polyurethane foam having a high cushioning property. A seat for a vehicle or the like is placed on a support frame. The pad surface is covered with an epidermis. In such a pad for a sheet, a reinforcing material such as a nonwoven fabric is integrated by foam molding of polyurethane foam in order to protect and reinforce the back surface of the pad body made of polyurethane foam from damage due to friction with the support frame. ing.

For example, the following Patent Document 1, basis weight 10 to 30 g / a thin dense layer of ^{m 2,} urethane foam molding reinforcement consisting of a nonwoven fabric formed by integrating the bulky layer in the coarse of basis weight 40 to 100 g / ^{m 2} A technique is disclosed in which the reinforcing material is integrated as a pad body side in contact with the polyurethane foam on the bulky layer side.

Patent Document 2 listed below uses a reinforcing material for foam molding which is made of a high-weight nonwoven fabric having a basis weight of 110 to 800 g / m ² and a fiber diameter of 1 to 16 d, and has a pressure-bonding layer on one surface side. Is disclosed in which the opposite surface of the pressure-bonding layer is integrated as the pad body side in contact with the polyurethane foam.

  In the techniques described in Patent Documents 1 and 2, the inner bulky layer is impregnated with polyurethane foam to increase the surface rigidity, and the outer dense layer clogs the air vent holes during foam molding with polyurethane foam. It plays a role of a filter to prevent the above.

On the other hand, in Patent Document 3 below, the layer in contact with the polyurethane foam is a dense nonwoven fabric having a basis weight of 20 to 100 g / m ² and a porosity of 87 to 91%, and the layer in contact with the coil spring or the like is 30 to 300 g / m ^2. And a pad for a sheet in which a polyurethane foam is foam-molded using a reinforcing material obtained by forming a bulky nonwoven fabric with a porosity of 90 to 94% and laminating and integrating them.

Further, the following Patent Document 4, a bulky nonwoven fabric layer of the porosity 90-94% and the upper and lower layers with basis weight 30 to 200 g / ^{m 2,} a basis weight 20 to 100 g / ^{m 2} in porosity from 87 to 91% of dense A sheet pad is disclosed in which polyurethane foam is foam-molded using a reinforcing material laminated and integrated with a nonwoven fabric layer as an intermediate layer.

In the techniques described in Patent Documents 3 and 4, the dense nonwoven fabric layer contributes to both the impregnation function and the blocking function during the foam molding of the polyurethane foam, and the bulky nonwoven fabric layer contributes to the urethane blocking property. The polyurethane foam is made so as not to come into direct contact with the coil spring. Therefore, it has the ability to prevent the seat pad from being lowered in rigidity and to prevent the generation of abnormal noise.
Japanese Utility Model Publication No. 62-26193 JP-A-2-258332 JP-A-6-171002 JP-A-6-171003

  The above conventional pad for a sheet uses a non-woven fabric as a reinforcing material, and the non-woven fabric is easily stretched due to its structure, so that there is a limit to the reinforcing effect on the back surface of the sheet pad. Also, if polyurethane penetrates into the reinforcing material and leaches out to the surface during foam molding of the pad body, abnormal noise will be generated due to rubbing with the support frame, so the occurrence of such abnormal noise is reliably prevented. There is a need.

  The present invention has been made in view of the above points, and provides a pad for a sheet that is excellent in reinforcing effect on the back surface of the pad and that can prevent the generation of abnormal noise due to scratching noise with the support frame. The purpose is to do.

  A seat pad according to a first aspect of the present invention is a seat pad comprising a pad body made of polyurethane foam and a reinforcing material integrated on the back surface of the pad body by foam molding of the polyurethane foam. The reinforcing material is formed by laminating and integrating a woven fabric layer made of woven fabric and a nonwoven fabric layer made of short fibers of 1 to 5 dtex by needle punching, and the woven fabric layer side is the pad main body side. It is characterized by being integrated with the pad body.

  A seat pad according to a second aspect of the present invention is a seat pad comprising a pad body made of polyurethane foam and a reinforcing material integrated on the back surface of the pad body by foam molding of the polyurethane foam. The reinforcing material is characterized in that a woven fabric layer made of woven fabric is used as an intermediate layer, and a nonwoven fabric layer made of short fibers of 1 to 5 dtex is used as upper and lower layers, and these are laminated and integrated by needle punching. .

  In the pad for a sheet according to the second invention, it is preferable that the reinforcing material has a fluff of 4/5 cm or more on the surface of the nonwoven fabric layer disposed on the pad body side.

In the pad for sheet | seat which concerns on the said 1st and 2nd invention, the fabric weight of the said nonwoven fabric layer is 20-300 g / m < ² >, Moreover, the air permeability of the said reinforcing material is 20-60 cm < ³ > / cm < ² > / s. Preferably there is.

  In the case of the sheet pad according to the first invention, during foam molding, the fabric layer disposed on the pad main body side becomes the first barrier layer of the polyurethane foam to reduce the penetration of the polyurethane. And since the nonwoven fabric layer arranged on the outside has a dense structure due to the fine denier of the short fibers, the polyurethane foam that has penetrated beyond the fabric layer is surely blocked in the nonwoven fabric layer, Foam oozing can be prevented. Therefore, it is possible to eliminate the generation of abnormal noise due to the rubbing noise with the support frame. Moreover, since the textile layer arrange | positioned at the pad main body side is reinforce | strengthened by impregnation of a polyurethane foam in addition to being harder than a nonwoven fabric in the first place, the high reinforcement effect of a pad back surface is acquired. In addition, since the reinforcing material can be produced at a lower cost than the reinforcing material generally formed by laminating two or more layers of the nonwoven fabric, the manufacturing cost of the sheet pad can be reduced.

  In the case of the sheet pad according to the second invention, in addition to the above-described effects of the first invention, a nonwoven fabric layer made of short fibers is provided between the fabric layer and the pad main body, so polyurethane foam Can be further reduced.

  Hereinafter, the pad for sheets concerning the embodiment of the present invention is explained in detail.

  FIG. 1 is a cross-sectional view of a reinforcing material in the first embodiment, FIG. 2 is an enlarged cross-sectional view of a main part of a seat pad using the reinforcing material, and FIG. 3 is a state in which the seat pad is attached to a support frame. FIG.

  As shown in FIG. 3, the seat pad 10 of the present embodiment is a cushion pad used for a seat surface portion of an automobile, and includes a pad body 12 made of a flexible polyurethane foam and a reinforcing material laminated and integrated on the back surface thereof. 14 and disposed on a metal support frame 50.

  The reinforcing material 14 is set in advance in the mold when the pad 10 for the sheet is molded, and the polyurethane foam raw material is injected into the mold and foamed to be integrated with the back surface of the pad main body 12. It is provided over the entire contact portion with the support frame 50. The support frame 50 has a substantially rectangular shape corresponding to the lower surface portion of the seat pad 10, and extends in the left-right direction to receive the front receiving surface portion 52 that receives the lower surface of the front portion of the pad 10 and the rear end portion of the pad 10. The rod 54 includes a spring 56 that is stretched between the front receiving surface portion 52 and the rod 54 and elastically supports the seating portion of the pad 10.

  As shown in FIG. 1, the reinforcing material 14 used in this embodiment is a two-layered sheet in which a woven fabric layer 20 made of a woven fabric and a nonwoven fabric layer 22 made of a short fiber web are laminated and integrated by needle punching. It is a fiber structure. In FIG. 1, the woven fabric layer 20 and the non-woven fabric layer 22 are shown as being completely separated, but both layers 20 and 22 are actually needle punched so that the short fibers of the non-woven fabric layer 22 are actually entangled in the structure of the woven fabric. In many cases, a part of the short fiber penetrates through the fabric layer 20 and is exposed on the back surface side, and the present invention includes such a case.

As the woven fabric constituting the woven fabric layer 20, in order to enhance the reinforcing effect on the pad for the sheet, a woven fabric comprising yarns made of long fibers is preferred, and in particular, a woven fabric made of polyolefin yarn such as polypropylene is preferably used. It is done. The fabric weight is preferably ²⁰ to 100 g / m ² , more preferably 40 to 80 g / m ² .

As the nonwoven fabric layer 22, a short fiber web made of short fibers of 1 to 5 dtex is used, more preferably a short fiber web of 1 to 3 dtex. By using such a short fiber web having a small fineness, the fiber structure in the nonwoven fabric layer 22 is densified, and the function of preventing the seepage of polyurethane can be enhanced. Here, the basis weight of the nonwoven fabric layer 22 is preferably ²⁰ to 300 g / m ² , more preferably 20 to 120 g / m ² , and still more preferably 30 to 100 g / m ² . If the basis weight of the nonwoven fabric layer 22 is less than 20 g / m ² , polyurethane may not be sufficiently prevented from seeping out. In addition, the kind of the short fiber which comprises the nonwoven fabric layer 22 is not specifically limited, For example, Polyolefin fibers, such as polyethylene and a polypropylene, Polyester fibers, such as a polyethylene terephthalate and a polybutylene terephthalate, Polyamides, such as polyamide 6 and the polyamide 66 System fibers and the like.

  When the fabric layer 20 and the nonwoven fabric layer 22 are laminated and integrated, the short fiber web is placed on the fabric, needle punched from the short fiber web side, and the short fibers are entangled with the constituent yarns of the fabric. Can be integrated so as not to peel off. The conditions of the needle punch change accordingly because the peel strength between the woven fabric layer 20 and the nonwoven fabric layer 22 and the air permeability of the reinforcing material 14 to be obtained change, so that they are set appropriately according to the target peel strength and air permeability. Can do. In addition, you may heat-press with respect to the obtained reinforcing material 14 after a needle punch process, and this raises the density of the reinforcing material 14, especially the nonwoven fabric layer 22 part, and has the effect of preventing the seepage of polyurethane. Can be increased.

Air permeability of the reinforcing member 14 thus obtained is preferably 20~60cm ³ / ^cm 2 / s, more preferably 30~40cm ³ / ^cm 2 / s. If the air permeability is less than 20 cm ³ / cm ² / s, there is a possibility that the air permeability required for the reinforcing material (gas venting function from the gas vent hole of the mold) may be insufficient, while 60 cm ³ / cm ^2. When it exceeds / s, there is a possibility that the function of preventing the seepage of polyurethane becomes insufficient.

  As shown in FIG. 2, the reinforcing member 14 is integrated with the pad body 12 with the fabric layer 20 side as the pad body 12 side. That is, at the time of foam molding of the sheet pad 10, when the reinforcing material 14 is set in the mold, the fabric layer 20 faces the polyurethane foam raw material side in the mold, and the nonwoven fabric layer 22 faces the mold molding surface side. Place it toward the. Then, the polyurethane foam raw material is injected into the mold and foamed, whereby the pad main body 12 is foam-molded integrally with the reinforcing material 14. At that time, the fabric layer 20 disposed on the pad main body 12 side becomes the first barrier layer of the polyurethane foam, and the penetration of the polyurethane is reduced to some extent. And since the nonwoven fabric layer 22 arranged on the outside has a dense structure due to fine denierization, the polyurethane foam that has penetrated beyond the fabric layer 20 is surely blocked in the nonwoven fabric layer 20, and the polyurethane foam Exudation can be prevented. Therefore, it is possible to eliminate the generation of abnormal noise due to the rubbing noise with the support frame 50.

  In addition, since the fabric layer 20 disposed on the pad body 12 side is reinforced by impregnation with polyurethane foam in addition to being less easily stretched than the nonwoven fabric, a high reinforcing effect on the back surface of the pad can be obtained.

  FIG. 4 is a cross-sectional view of a reinforcing material in the second embodiment, and FIG. 5 is an enlarged cross-sectional view of a main part of a sheet pad using the reinforcing material. Similarly to the first embodiment, the seat pad according to the second embodiment is attached to the support frame 50 as shown in FIG.

  In the seat pad of the second embodiment, the configuration of the reinforcing material integrated with the back surface of the pad main body 12 is different from that of the first embodiment. That is, the reinforcing material 14A in the second embodiment is laminated and integrated by needle punching using the woven fabric layer 30 made of woven fabric as an intermediate layer and the nonwoven fabric layers 32 and 34 made of short fibers of 1 to 5 dtex as upper and lower layers. A sheet-like fiber structure having a three-layer structure.

Here, the fabric layer 30 can be made of the same fabric as the fabric layer 20 in the first embodiment. In addition, the upper and lower nonwoven fabric layers 32 and 34 can be constituted by a short fiber web similar to the nonwoven fabric layer 22 in the first embodiment. Furthermore, the method of laminating and integrating these three layers can also be performed by the needle punch similar to that of the first embodiment. A woven fabric is placed on the short fiber web, and the needle punch is placed on the short fiber web. Just do it. Further, air permeability of the reinforcing member 14A of the resulting three-layer structure is preferably 20~60cm ³ / ^cm 2 / s, more preferably 30~40cm ³ / ^cm 2 / s.

  In order to integrate the reinforcing material 14A into the pad main body 12, when the sheet pad 10 is foam-molded, the reinforcing material 14A is set in a mold, and a polyurethane foam raw material is injected into the mold to be foam-molded. At that time, the upper and lower nonwoven fabric layers 32 and 34 having a dense structure by fine denier and the fabric layer 30 between them can surely prevent the polyurethane foam from oozing out. It is possible to eliminate the generation of abnormal noise due to the noise. In addition, since the fabric layer 30 as the intermediate layer is reinforced by impregnation with polyurethane foam in addition to being harder to stretch than the nonwoven fabric, a high reinforcing effect on the back surface of the pad can be obtained.

  In this case, it is preferable that the reinforcing material 14A has at least 4/5 cm, more preferably 6/5 cm or more, and more preferably fuzz on the surface of the nonwoven fabric layer 34 side disposed on the pad body 14 side. Is 10-50 pieces / 5 cm or more. The evaluation method for fluff is the number of fibers having a length of 5 mm or more from the surface of the nonwoven fabric at the crease part by folding the sample (reinforcing material 14A) having a width of 5 cm in half so that the nonwoven fabric layer 34 appears outside (See paragraph [0024] of JP-A-2001-11767).

  Thus, by making the nonwoven fabric layer 34 arranged on the pad main body 12 side a layer having a lot of fluff on the surface, the fluff enters the polyurethane foam at the time of foaming molding of the polyurethane foam, and has high adhesive strength with the pad main body 12. Can be obtained.

In addition, the nonwoven fabric layers 32 and 34 may have the same basis weight in the upper and lower sides, or may have different basis weights in the upper and lower sides. When the basis weight is different between the upper and lower sides, the basis weight of the lower nonwoven fabric layer 34 disposed on the pad main body 12 side is made smaller than the basis weight of the upper nonwoven fabric layer 32 disposed on the support frame 50 side, thereby providing an intermediate layer. While enhancing the reinforcement effect of the polyurethane foam impregnated in the fabric layer 30, it is possible to reliably prevent the polyurethane foam from penetrating beyond the fabric layer 30. In this case, the basis weight of the lower nonwoven fabric layer 34 is preferably 20 to 60 g / m ² , and the upper nonwoven fabric layer 32 is preferably 20 to 90 g / m ² . In the sum of the two nonwoven layers 32 and 34 is preferably a basis weight 40~300g / ^{m 2,} more preferably from 60~120g / ^{m 2.}

  Examples will be described below, but the present invention is not limited to such examples.

(First embodiment)
A polypropylene short fiber web is placed on a polypropylene fabric having a basis weight of 60 g / m ² , and both are laminated and integrated by needle punching to produce a reinforcing material 14 having a two-layer structure of Examples 1 to 7 and Comparative Example 1. did. At that time, a part of the reinforcing materials was subjected to hot pressing by calendering with a hot roll at 170 ° C. to increase the density. The fineness and basis weight of the used short fiber nonwoven fabric, the presence or absence of hot pressing, and the air permeability of the obtained reinforcing material are as shown in Table 1 below.

  The air permeability in Table 1 was measured according to JIS L 1096 8.27.1 A method (Fragile method).

  In the mold, the reinforcing material 14 obtained above is arranged with the fabric layer 20 facing the polyurethane foam raw material side in the mold and the nonwoven fabric layer 22 facing the upper surface of the mold (the upper mold cavity surface). According to a conventional method, a polyurethane foam raw material was injected into a mold and foam-molded to produce a sheet pad 10 in which a reinforcing material 14 was laminated and integrated on the back surface of the pad body 12.

  The prepared sheet pad was cut and the state of impregnation and leaching of the polyurethane foam was observed. The results are shown in Table 1. In the table, “◯” means that no oozing occurred, “Δ” means that oozing was slightly observed, and “X” means that oozing was recognized.

In addition, the prepared seat pad was attached to the front seat of an automobile, and 10 panelists traveled at high speed to evaluate the presence or absence of scratching noise. The results are shown in Table 1. In the table, “◯” means that no scratching sound is present, “Δ” means that a slight scratching sound is recognized, and “X” means that a scratching sound is recognized.

(Second Embodiment)
Polypropylene short fiber webs are stacked on both upper and lower sides of a polypropylene fabric having a basis weight of 60 g / m ² and laminated and integrated by needle punching to obtain the reinforcing material 14A having the three-layer structure of Examples 8 and 9 and Comparative Example 2. Produced. The fineness and basis weight of the upper and lower nonwoven fabric layers 32, 34, the air permeability of the obtained reinforcing material 14A, and the fluffing of the surface on the nonwoven fabric layer 34 side are as shown in Table 2 below. In addition, the measuring method of fluff is as above-mentioned.

  The reinforcing material 14A is placed on the cavity surface of the upper mold in the mold, and polyurethane foam raw material is injected into the mold in accordance with a conventional method to perform foam molding, and the reinforcing material 14A is laminated and integrated on the back surface of the pad body 12. A sheet pad was prepared. The obtained pad for sheet was observed for the impregnation and seepage state of polyurethane foam and evaluated for the presence or absence of scratching noise caused by high-speed running of the actual vehicle. The results are shown in Table 2.

In addition, the adhesive strength between the pad main body 12 and the reinforcing material 14A is determined by using an Instron type tensile tester for a sample of thickness 10 mm × width 25 mm × length 150 mm (thickness is reinforcing material + urethane). Measured in minutes. The results are shown in Table 2.

It is sectional drawing of the reinforcing material in the 1st Embodiment of this invention. It is a principal part expanded sectional view of the pad for sheets concerning the embodiment. It is sectional drawing which shows the state with which the pad for the sheet | seat was mounted | worn to the support frame. It is sectional drawing of the reinforcing material in 2nd Embodiment. It is a principal part expanded sectional view of the pad for sheets concerning the embodiment.

Explanation of symbols

10 …… Pad for sheet 12 …… Pad body 14,14A …… Reinforcing material 20,30 …… Fabric layer 22,32,34 …… Nonwoven fabric layer

Claims (4)

A pad for a sheet comprising a pad body made of polyurethane foam and a reinforcing material integrated by foam molding of the polyurethane foam on the back surface of the pad body,
The reinforcing material is formed by laminating and integrating a woven fabric layer made of woven fabric and a non-woven fabric layer made of short fibers of 1 to 5 dtex by needle punching, and the woven fabric layer side is the pad main body side. A seat pad that is integrated with the main body. A pad for a sheet comprising a pad body made of polyurethane foam and a reinforcing material integrated by foam molding of the polyurethane foam on the back surface of the pad body,
The sheet pad, wherein the reinforcing material comprises a woven fabric layer made of a woven fabric as an intermediate layer, and a nonwoven fabric layer made of short fibers of 1 to 5 dtex as an upper and lower layers, and these are laminated and integrated by needle punching.   The pad for sheets according to claim 2, wherein the reinforcing material has a fluff of 4/5/5 cm or more on the surface of the nonwoven fabric layer disposed on the pad main body side. The basis weight of the nonwoven fabric layer is 20 to 300 g / m ² , and the air permeability of the reinforcing material is 20 to 60 cm ³ / cm ² / s. Seat pad.

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