JP2004353153A - Foamed molded product reinforcing material and car seat - Google Patents
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Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は、ウレタン発泡、等の成形用補強材と車両用座席に関するものである。特に車両等の座席クッション材剛性の低下を防止し、ポリウレタンフォームとバネ間の摩擦により発生する摩擦音発生を防止し、静粛性、補強効果及び成形性に優れた、シート目付のバラツキが少ない車両用シート等のウレタン発泡補強基布及びそれを用いて得る成形性ポリウレタン、等の座席用クッション材と車両用座席に関するものである。
【０００２】
【従来の技術】
車両用等のクッション材は、軟質ポリウレタンフォーム型内発泡成形品が主流として用いられている。このようなクッション材が良好なクッション性を実現するためには、一般に多く用いられる図１に示すようなクッション材構造において、人体に接する最上層Ａ（基材層）は柔らかいものでなければならないが、次に存在する層Ｂ（緻密層）は熱成形性をもった材料であるべきで、Ｂ層を受け衝撃的な力を吸収しバネ感覚を生ずるスプリングＣ層（基材層）のクッション作用を、均等に分散し、Ｂ層を平らに保ち支えて上下動するような構造と作用が必要である。
また、このような軟質ポリウレタンフォーム型内発泡成形品の耐久性を確保する面からも、バネが接しポリウレタンフォームが摩擦され、局部的応力を受け損傷することを避けるため、従来次のようなポリウレタンフォームのバネ材接触面側に補強基布を入れ、良好なクッション性の確保をはかるとともに耐久性をも確保して来た。
即ち、その代表的事例を掲げると、補強材としてスラブウレタンと寒冷紗を用い、発泡成形金型面に接するようにスラブウレタンを設置し、その内側に寒冷紗を設置しウレタン液を注入し、加熱加圧し発泡させて補強層が挿入された軟質ポリウレタンフオーム型内発泡成形品を製造する方法が多く用いられ主役の座を占めていた。
この方法におけるスラブウレタンの役割は、得られるクッション材への剛性の付与とともに、ウレタン流入による発泡金型空気抜き孔の閉塞防止にあり、寒冷沙の役割は発泡し膨張してくるポリウレタンを容易に透過し、寒冷紗が、容易にポリウレタンフォーム内に包埋一体化され、引張り弾性率を改善し優れた補強層を形成することにある。
【０００３】
しかしながら、スラブウレタンによる剛性改善効果が不充分であると共に、何よりも工数が多く作業が煩雑であること、及び補強布である寒冷紗が、成形品のなす３次曲面形状に沿い難いという難点があった。
次いで、前記寒冷紗の成形形状に沿い難いという難点解消とコストダウンを目的とし開発され主役の座に就いたのは、不織布（反毛フェルト）である。
この不織布が、補強布としての要求特性を満たすためには、発泡し膨張してくるウレタン液の適度の透過性を有することが必要で、このためには適度のポアーサイズの空隙孔と空隙率（見掛け嵩密度）を有することが必要であり、又充分な補強効果と剛性を付与するためにも、発泡し膨張してくるポリウレタン内に不織布が包埋されポリウレタンで不織布交点が再結合され、不織布組織内にポリウレタンフォームが充填され適度な剛性と高い引張り弾性率を発揮する適度の見掛け嵩密度（空隙率）が必要であり、更に、成形品曲面形状への順応性確保のため、不織布構成繊維交点間の接着を比較的緩やかに行ない、組織変形の自由度を持たしめることが必要であった。
【０００４】
このような観点から、適切な嵩密度、空隙率を有する不織布が、試行錯誤的に検討され開発され使用されてきた。
これらの補強用不織布における嵩密度、空隙率設定の基準は、発泡し膨張してくるポリウレタンが不織布前面にわたり透過し、不織布表面をポリウレタン皮膜が覆えるような比較的高い透過性を有するように選定し、透過性が高すぎ成形金型の空気抜き孔にまでポリウレタンが流入することのないレベルに抑制することに留意して選定されている。
以上が軟質ポリウレタンフォーム型内発泡成形用補強布の主流である。
しかしながら、より緩やかな管理下において安定してポリウレタンの必要且つ充分な透過性を確保し、成形金型空気抜き孔へのポリウレタン流入を完全に防止し、高収率、高生産性で生産を行なえ、ウレタン樹脂の含浸、透過性が良く、剛性アップと補強に寄与し、ウレタンフォームと補強布間の一体化能の高い補強布を得るため、嵩密度の低い補強用不織布層と、膨張してくるポリウレタンの金型空気抜き孔への流入を遮断するに充分な、比較的高い嵩密度を有する不織布層を遮断層として設けて、積層一体化した補強用不織布が開発された（特許文献１）。
【０００５】
【特許文献１】
実公昭６２−２６１９３公報
【０００６】
更に、補強効果とポリウレタン流入による空気抜き孔閉鎖防止効果を強化するため、高目付不織布を補強用基布として用い、高い補強効果と、高目付化によるポリウレタンの空気抜き孔への流入を遮断、防止する方法、更には、その高目付け不織布の片面をエンボス加工等により高密度化し、遮断層を積層せずに設け（特許文献２）、或いはポリウレタンの空気抜き孔への流入防止をより確実にして用いる方法（特許文献３）等も発明され開発されている。
しかしながら発泡ウレタンと接触する基布の層が、ウレタン含浸向上をねらった高目付で嵩高な構造のため、過度のウレタンの含浸充填を招き、結果としてウレタン発泡成形品のウレタン密度低下による剛性低下を誘発するという問題がある。
また深絞りタイプの発泡部材については、成形後補強材にシワが多く発生してバネ擦れによる異音発生原因や局所的に圧力が高くなり目付の薄い部分での樹脂抜けを発生させる原因ともなった。
【０００７】
【特許文献２】
実公昭６２−２６１９３号公報
【特許文献３】
特開平２−２５８３３２号公報
【０００８】
【発明が解決しようとする課題】
本発明では上記従来の技術の問題点を解決し、ウレタン発泡成形時でのシワ及び樹脂抜けによる異音防止抑制、優秀な補強効果と優れたウレタン成形性を付与するすることのできるバネ受け補強材及び車両用座席を提供するものである。
【０００９】
【課題を解決するための手段】
本発明は、以下の構成を採用するものである。すなわち、
１．下記特性の補強材であることを特徴とする発泡成形用補強材。
通気度：４００ｃｃ／ｓｅｃ．／ｃｍ２以下
厚さ：１．０ ｍｍ以上、
目付バラツキＣＶ値：１０％以下、
６５℃時５％伸張時のシート応力：０．５〜２０Ｎ／５ｃｍ、
１００℃時５％伸張時のシート応力：０．２５〜１０Ｎ／５ｃｍ
２．繊維径が４０μ以下の繊維からなる交絡処理されてなる長繊維不織布を主体としてなることを特徴とする上記第１記載の発泡成形体補強材。
３．交絡処理が、機械交絡法もしくは水流交絡法により処理されたものであることを特徴とする上記第１記載の発泡成形体補強材。
４．補強材が緻密層と基材層の２層構造であることを特徴とする上記第１記載の発泡成形用補強材。
５．補強材が基材層、緻密層及び基材層の３層構造であることを特徴とする上記第１記載の発泡成形用補強材。
６．緻密層の目付が５０ｇ／ｍ２以下、見掛密度が０．０５〜０．４０ｇ／ｃｍ３であり、基材層の目付が３０ｇ／ｍ２以上、見掛密度が０．０１〜０．３ｇ／ｃｍ３であることを特徴とする上記第４又は５記載の発泡成形用補強材。
７．緻密層が、繊維径が１０μ以下のメルトブローン不織布であることを特徴とする上記第４又は５記載の発泡成形用補強材。
８・緻密層が、鞘に低融点成分を配した芯鞘型複合繊維からなる不織布であることを特徴とする上記第４又は５記載の発泡成形用補強材。
９．緻密層が、ポリトリメチレンテレフタレート、ポリブチレンテレフタレート繊維、ポリウレタン繊維、もしくはポリエステル系エラストマーのいずれかの繊維からなる不織布であることを特徴とする上記第４又は５記載の発泡成形用補強材。
１０．基材層が、リン原子を含有量で１００〜５００００ｐｐｍ共重合してなる難燃性ポリエステル繊維からなる不織布であることを特徴とする上記第４又は５記載の発泡成形用補強材。
１１．発泡成形用補強材が、ポリウレタンフォームからなる車両用座席と当該座席を支持するバネ材との中間に配されてなることを特徴とする上記第１記載の発泡成形用補強材。
１２．上記第１記載の発泡成形用補強材が、ポリウレタンフォームからなる車両用座席のバネ材接触面側に積層されてなることを特徴とする車両用座席。
【００１０】
まず補強材シートの通気度が４００ｃｃ／ｓｅｃ．／ｃｍ２以下である。４００ｃｃ／ｓｅｃ．／ｃｍ２を超えると、いくら成形性に優れていても、部材より樹脂抜けが発生してそれがバネにこすれて異音が発生してしまう。好ましくは０．１〜４００ｃｃ／ｓｅｃ．／ｃｍ２、更に好ましくは０．１〜３００ｃｃ／ｓｅｃ．／ｃｍ２以下である。
見かけ厚さは１．０ｍｍ以上である。１．０ｍｍ以下になると樹脂がの反応が層途中で停止せずに表面付近に析出してしまう。好ましくは１．５ｍｍ以上、より好ましくは２．０ｍｍ以上４．０ｍｍ以下である。
シート目付のバラツキはＣＶ（変動値）１０％以下である。１０％を超えるとムラにより樹脂漏れが発生してしまう。好ましくは０．１〜１０％、更に好ましくは０．１〜５％である。
【００１１】
高級車で使用されるウレタンシートを製造するコールドタイプのウレタン発泡機は６５℃付近で発泡させる場合が多い。その場合６５℃時５％伸張時のシート応力０．５〜２０Ｎ／５ｃｍが適している。シート応力が２０Ｎ／５ｃｍを超えると、特に深絞りタイプの発泡において湾曲部で補強材表面への樹脂漏れ及びシワが発生してしまう。好ましくは１０Ｎ／５ｃｍ以下より好ましくは０．５〜５Ｎ／５ｃｍである。
低級車で使用されるウレタンシートを製造するホットタイプのウレタンの発泡機は１００℃付近で発泡させる場合が多い。その場合１００℃時５％伸張時のシート応力が０．５〜１０Ｎ／５ｃｍである。シート応力が１０Ｎ／５ｃｍを超えると、特に深絞りタイプの発泡において湾曲部で補強材表面への樹脂漏れ及びシワが発生してしまう。好ましくは５Ｎ／５ｃｍ以下より好ましくは０．２５〜３Ｎ／５ｃｍである。
【００１２】
緻補強材が緻密層と基材層の２層または３層構造である事が好ましい。単層のみになると目付ムラが大きく、樹脂抜けが多く発生する。また単層のためバネがウレタン層に接触する可能性が大きく異音が発生してしまう。緻密層によってウレタンを面で止めて基材層によってバネの擦れの異音を防いでいる。
３層タイプの場合は緻密層が中間層になり、樹脂抜けを中間層でとめて上下層で嵩高性を発現してベネによる擦れの異音を防いでいる。
緻密層の目付が４０ｇ／ｍ２以下である。４０ｇ／ｍ２を超えると成形性が悪くなり、深絞りタイプの成形機で樹脂抜けが発生する。好ましくは３０ｇ／ｍ２以下、より好ましくは目付１５〜２０ｇ／ｍ２である。
【００１３】
見掛密度が０．０５〜０．５０ｇ／ｃｍ３である。見掛け密度が０．０５ｇ／ｃｍ３以下になると樹脂抜けを発生してしまう。見掛密度が０．５０ｇ／ｃｍ３以上になると成形性が悪くなり、特に深絞りタイプで樹脂抜けが発生してしまう。好ましくは０．１〜０．４ｇ／ｃｍ３より好ましくは０．２〜０．３ｇ／ｃｍ３である。
基材層の目付が３０ｇ／ｍ２以上である。３０ｇ／ｍ２未満になると緻密層で止められたウレタン層との距離が近くなりバネによる異音が発生してしまう。好ましくは５０ｇ／ｍ２以上１００ｇ／ｍ２以下である。
見掛密度は０．０１〜０．３ｇ／ｃｍ３である。見掛け密度が０．０１ｇ／ｃｍ３ 未満になるとバネが直接緻密層に止められたウレタン層に接触する機会が増え、擦れ音による異音を発生してしまう。０．３ｇ／ｃｍ３を超えると成形性を阻害してしまう。
【００１４】
緻密層の繊維径は０．１〜４０μである。４０μを超えるとウレタンを緻密層面で止めることができず樹脂漏れを発生さしてしまう。好ましくは４０μ以下、より好ましく０．１〜２０μである。または繊維径が１０μ以下のメルトブローン不織布であることも好ましい。
【００１５】
緻密層に使用される部材はスパンボンド不職布、短繊維不織布両方可能である。用いられる繊維はポリエチレンテレフタレート（以下ＰＥＴ）、ポリトリメチレンテレフタテート（以下ＰＴＴ）、ポリブチレンテレフタレート（以下ＰＢＴ）、ポリエステルエラストマー（以下ＰＥＬ）、ポリプロピレン（以下ＰＰ）、オレフィン系エラストマー、ポリエチレン（以下ＰＥ）、ナイロン、ビニロン、塩化ビニリデン、レーヨン、コットン等の天然繊維、低融点成分（２成分以上）を含んだ芯／鞘構造繊維 ＰＥＴ／ＰＥ，ＰＥＴ／低融点イソフタル酸共重合ＰＥＴ、ＰＥＴ／低融点メタロセン触媒使用ＰＰ、ＰＥＴ／ＰＥＬ、ＰＰ／低融点メタロセン触媒使用ＰＰ ，或いは低融点成分を含んだ混繊繊維である。好ましくはＰＰおよびＰＥＴスパンボンド、より好ましくはポリトリメチレンテレフタレート、ポリブチレンテレフタレート繊維、ポリウレタン繊維、もしくはポリエステル系エラストマーである。より好ましくは低融点成分（２成分以上）を含んだ芯／鞘構造繊維スパンボンド不職布である。
基材層に使用される部材はスパンボンド不織布に用いられるのはスパンボンド不職布、短繊維不織布両方可能である。用いられる繊維はＰＥＴ、ＰＢＴ、ＰＴＴ、ＰＥＬ、ＰＰ、オレフィン系エラストマー、ＰＥ、ナイロン、ビニロン、塩化ビニリデン、レーヨン、コットン等の天然繊維である。好ましくはポリトリメチレンテレフタレート、ポリブチレンテレフタレート繊維、ポリウレタン繊維、もしくはポリエステル系エラストマー不織布である。より好ましくはＰＥＴ不職布である。
【００１６】
また基材層が、リン原子を含有量で１００〜５００００ｐｐｍ共重合してなる難燃性ポリエステル繊維からなる不織布である。リン原子が１００ｐｐｍ以下であればＦＭＶＳＳの基準を合格できない５００００ｐｐｍ以上であればバネの擦れによって繊維が破断してしまう。好ましくは ５００ 〜８，０００ｐｐｍである。
【００１７】
上記の発泡成形用補強材は、ポリウレタンフォームからなる車両用座席と当該座席を支持するバネ材との中間に配置される。具体的には、当該補強材は、ポリウレタンフォームからなる車両用座席のバネ材接触面側に積層され、ポリウレタンフォームとバネ間の摩擦により発生する摩擦音発生を防止し、静粛性、補強効果及び成形性に優れた、シート目付のバラツキが少ない車両用シート等の座席用クッション材や車両用座席となす。
【００１８】
【実施例】
以下実施例により、本発明を具体的に説明する。しかしながら本発明はこれによって 限定されるものではない。なお以下の実施例などの評価および特性値は、以下の測定法 によった。
（１）目付及びＣＶ値（ｇ／ｍ２、％）
サンプルサイズ ５ｃｍ巾ｘ２０ｃｍ 原反巾方向に５ｃｍ間隔で１０点、長さ方向については前記横方向サンプルプリングを１０００ｍ各間隔で１０個所行った。（計 １００点）
ＣＶ値＝（標準偏差／平均値）Ｘ１００（％）
（２）厚さ（ｍｍ）
上記サンプルサイズの中央長さ方向中央付近を測定する。１００点の平均値。
荷重は２ｇ／ｃｍ２（荷重面積 ４ｃｍ２）
（３）見かけ密度（ｇ／ｃｍ３）
目付（ｇ／ｍ２）／（ 上記厚さ（ｃｍ）ｘ１００ｘ１００）
（４）熱時強度（ＳＴ５）（Ｎ／５ｃｍ）
加熱テンシロン機を用いてチャック間距離１０ｃｍ、ヘッドスピード１０ｃｍ／ｍｉｎ．で評価した。
▲１▼温度 ６５℃ｘ１ｍｉｎ．、１００℃ｘ１ｍｉｎ．
▲２▼ＳＴ５：５％伸長時の強度
（５）通気度（ｃｃ／ｃｍ２・ｓｅｃ）
ＪＩＳＬ１０９６に準じたフラジール通気度測定機によって行った。
【００１９】
（実施例１）
スパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを１７０℃の熱ロールによるカレンダー加工で加熱圧着した不織布（上下層）、同じくスパンボンド法により製造された２．２デシテックスの芯鞘重量比（１：１）の２成分繊維（芯：ポリエチレンテレフタレート、融点２６０℃、鞘：イソフタル酸を共重合したコポリエステル、融点１３０℃）よりなるランダムループ組織の目付２０ｇ／ｍ２ のウェッブ（中間層）を、ニードルパンチ機を用い交絡し一体化し、嵩高積層構造不織布を得た。
【００２０】
（実施例２）
スパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを１７０℃の熱ロールによるカレンダー加工で加熱圧着した不織布と、同じくスパンボンド法により製造された２．２デシテックスの芯鞘重量比（１：１）の２成分繊維（芯：ポリエチレンテレフタレート、融点２６０℃、鞘：ポリプロピレン共重合体、融点１８０℃）よりなるランダムループ組織の目付２０ｇ／ｍ２ のウェッブを、ニードルパンチ機を用い交絡し一体化し、嵩高積層構造不織布を得た。
【００２１】
（実施例３）
スパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを１７０℃の熱ロールによるカレンダー加工で加熱圧着した不織布と、同じくスパンボンド法により製造された２．２デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを、ニードルパンチ機を用い交絡し一体化し、嵩高積層構造不織布を得た。
【００２２】
（実施例４）
スパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２のウェッブを１７０℃の熱ロールによるカレンダー加工で加熱圧着した不織布と、メルトブロー法により製造された０．１デシテックスのポリポロピレン不織布よりなる目付２０ｇ／ｍ２のウェッブを、ニードルパンチ機を用い交絡し一体化し、嵩高積層構造不織布を得た。
【００２３】
（実施例５）
スパンボンド法により製造された２．２デシテックスのポリブチレンテレフタレート繊維よりなるランダムループ組織の目付１００ｇ／ｍ２ のウェッブを１５０℃の熱ロールによるカレンダー加工で加熱圧着した、ニードルパンチ機を用い交絡し、嵩高性を発現して不織布を得た。
【００２４】
（実施例６）
スパンボンド法により製造された３．３デシテックスのポリトリメチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを１５０℃の熱ロールによるカレンダー加工で加熱圧着した不織布（上下層）と、同じくスパンボンド法により製造された２．２デシテックスのポリトリメチレンテレフタレート繊維よりなるランダムループ組織の目付２０ｇ／ｍ２ のウェッブを、ニードルパンチ機を用い交絡３層一体化し、嵩高積層構造不織布を得た。
【００２５】
（実施例７）
スパンボンド法により製造された２．２デシテックスのポリブチレンレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを１５０℃の熱ロールによるカレンダー加工で加熱圧着した不織布（上下層）と、同じくスパンボンド法により製造された２．２デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付２０ｇ／ｍ２ のウェッブを、ニードルパンチ機を用い交絡３層一体化し、嵩高積層構造不織布を得た。
【００２６】
（比較例１）
スパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付８０ｇ／ｍ２ のウェッブを１７０℃の熱ロールによるカレンダー加工で加熱圧着した不織布と、同じくスパンボンド法により製造されたの２．２デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付４０ｇ／ｍ２ のウェッブを２００℃の熱ロールによるカレンダー加工で加熱圧着した不織布を、ニードルパンチ機を用い交絡し一体化し、積層構造不織布を得た。
【００２７】
（比較例２）
スパンボンド法により製造された１．７デシテックスのポリプロピレン繊維よりなるランダムループ組織の目付２０ｇ／ｍ２ のウェッブを熱ロールによるカレンダー加工で加熱圧着した不織布と、同じくスパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付２０ｇ／ｍ２ のウェッブを２００℃の熱ロールによるカレンダー加工で加熱圧着した不織布をニードルパンチ機を用い交絡し一体化し、積層構造不織布を得た。
【００２８】
（比較例３）
スパンボンド法により製造された３．３デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付８０ｇ／ｍ２ のウェッブを１７０℃の熱ロールによるカレンダー加工で加熱圧着した不織布と、同じくスパンボンド法により製造された６．６デシテックスのポリエチレンテレフタレート繊維よりなるランダムループ組織の目付８０ｇ／ｍ２ のウェッブを２００℃の熱ロールによるカレンダー加工で加熱圧着した不織布を、ニードルパンチ機を用い交絡し一体化し、積層構造不織布を得た。
【００２９】
【表１】
【表２】
成形性：× シワがＲ部に多く発生、△ シワがＲ部に部分的に発生、○ シワが無くＲ部分が形成されている
ウレタン染み出し：× Ｒ部、平面に多くの染み出しが発生する、△ Ｒ部に染み出しが発生する、○ 染みだしが全く見られない
バネ擦れ破断：× ウレタン部まで表面が磨耗されている、△ 所々表面が毛羽立っている、○ 毛羽立ちがほとんど見られない
バネ擦れ異音：× 乗車時つねに音がする、△ 冬季にのみ音がすることがある、○ ほとんど音がしない
補強材ハンドリング性：× 成形型にセットできない、△ 持つ場所によって型にセットできない時がある、○ 容易に型にセットすることができる
ＦＭＶＳＳ難燃試験： × 不合格、○ 合格
【００３２】
【発明の効果】
本発明によると、車両等の座席クッション材剛性の低下を防止し、ポリウレタンフォームとバネ間の摩擦により発生する摩擦音発生を防止し、静粛性、補強効果及び成形性に優れたシート目付のバラツキが少ない車両用シート等の発泡成形体補強材及び車両用座席を提供することを可能とした。
【図面の簡単な説明】
【図１】バネ受け材の構造を示す概略図。
【符号の説明】Ａ層：基材層（嵩高層）、Ｂ層：緻密層（成形層）、Ｃ層：基材層（嵩高層）[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a reinforcing material for molding such as urethane foam and a vehicle seat. Especially for vehicles such as vehicles, which prevent the rigidity of the seat cushion material from lowering, prevent the generation of friction noise generated by the friction between the polyurethane foam and the spring, and are excellent in quietness, reinforcing effect and formability, and with less variation in seat weight. The present invention relates to a seat cushion material such as a urethane foam reinforced base fabric such as a seat and a moldable polyurethane obtained by using the same, and a vehicle seat.
[0002]
[Prior art]
As a cushion material for vehicles and the like, a flexible polyurethane foam-type foam molded article is mainly used. In order for such a cushioning material to achieve good cushioning properties, in the cushioning material structure generally used as shown in FIG. 1, the uppermost layer A (base material layer) in contact with the human body must be soft. However, the next layer B (density layer) should be made of a material having thermoformability. The cushion of the spring C layer (base layer) which receives the B layer and absorbs an impact force to generate a spring feeling. It is necessary to have a structure and an action which distributes the action evenly and moves up and down while keeping the layer B flat.
Also, from the viewpoint of ensuring the durability of such a foamed molded product in a flexible polyurethane foam mold, in order to prevent the polyurethane foam from being rubbed by the spring and being rubbed by the local stress and being damaged by the local stress, the following polyurethane is conventionally used. A reinforcing base cloth has been placed on the side of the foam material contacting the spring material to ensure good cushioning properties and durability.
That is, as a typical example, slab urethane and cold gauze are used as reinforcing materials, slab urethane is installed so as to be in contact with the foam molding die surface, cold gauze is installed inside thereof, urethane liquid is injected, and heating and heating are performed. A method of producing a foamed article in a flexible polyurethane foam mold in which a reinforcing layer is inserted by foaming by pressing is widely used, and has taken the leading role.
The role of the slab urethane in this method is to provide rigidity to the obtained cushioning material and to prevent the foaming mold air vent holes from being clogged by the inflow of urethane. The cold gauze is easily embedded and integrated in the polyurethane foam to improve the tensile modulus and form an excellent reinforcing layer.
[0003]
However, the slab urethane has an insufficient rigidity improving effect, has a lot of man-hours and is complicated, and it is difficult for the cold cloth, which is a reinforcing cloth, to conform to the cubic curved surface shape of the molded product. Was.
Next, a nonwoven fabric (anti-hair wool felt) was developed for the purpose of solving the difficulty of following the shape of the cold gauze and reducing costs, and taking the lead role.
In order for the nonwoven fabric to satisfy the required properties as a reinforcing cloth, it is necessary that the nonwoven fabric has an appropriate permeability of the urethane liquid that expands and expands. For this purpose, the pores and the porosity of an appropriate pore size ( (Apparent bulk density), and in order to provide sufficient reinforcing effect and rigidity, the non-woven fabric is embedded in the foaming and expanding polyurethane, and the non-woven fabric intersection is recombined with the polyurethane. Polyurethane foam is filled in the tissue, it needs to have appropriate rigidity and moderate apparent bulk density (porosity) to exhibit high tensile elasticity. In addition, in order to ensure adaptability to the curved surface of the molded product, non-woven fabric fibers It was necessary to make the adhesion between the intersection points relatively gradual and to have a degree of freedom in tissue deformation.
[0004]
From such a viewpoint, nonwoven fabrics having an appropriate bulk density and porosity have been studied, developed and used by trial and error.
The criteria for setting the bulk density and porosity of these non-woven fabrics for reinforcement are selected so that polyurethane that expands and expands penetrates over the front surface of the non-woven fabric and has a relatively high permeability so that the polyurethane film covers the non-woven fabric surface. However, it is selected in consideration of the fact that the permeability is so high that the polyurethane does not flow into the air vent hole of the molding die.
The above is the mainstream of the reinforcing cloth for foam molding in a flexible polyurethane foam mold.
However, under a more moderate control, the necessary and sufficient permeability of the polyurethane is ensured stably, the polyurethane is completely prevented from flowing into the air vent of the molding die, and the production can be performed with high yield and high productivity. Urethane resin impregnation, good permeability, contributes to increase rigidity and reinforcement, and to obtain a reinforcing cloth with high integration ability between urethane foam and reinforcing cloth, expands with a reinforcing nonwoven fabric layer with low bulk density. A reinforcing non-woven fabric has been developed in which a non-woven fabric layer having a relatively high bulk density, which is sufficient to block the inflow of polyurethane into the mold air vent hole, is provided as a blocking layer and laminated and integrated (Patent Document 1).
[0005]
[Patent Document 1]
Japanese Utility Model Publication No. 62-26193 [0006]
Furthermore, in order to reinforce the reinforcing effect and the effect of closing the air vent hole due to the inflow of polyurethane, a high-weight nonwoven fabric is used as a reinforcing base cloth to block and prevent the polyurethane from flowing into the air vent hole due to the high reinforcing effect and the high weight. A method of further increasing the density of one surface of the nonwoven fabric by embossing or the like, providing a blocking layer without laminating (Patent Literature 2), or using more reliably preventing polyurethane from flowing into the air vent hole. (Patent Document 3) and the like have also been invented and developed.
However, since the base fabric layer in contact with the urethane foam has a bulky and bulky structure aimed at improving urethane impregnation, it causes excessive urethane impregnation and filling, and as a result, rigidity decreases due to a decrease in urethane density of the urethane foam molded article. There is a problem of triggering.
In addition, for the deep-drawing type foamed member, many wrinkles were generated in the reinforcing material after molding, which caused abnormal noise due to spring rubbing and locally increased pressure, which also caused resin to escape in thin portions with a small basis weight. .
[0007]
[Patent Document 2]
Japanese Utility Model Publication No. 62-26193 [Patent Document 3]
JP-A-2-258332
[Problems to be solved by the invention]
The present invention solves the above-mentioned problems of the prior art, and suppresses abnormal noise caused by wrinkles and resin detachment during urethane foam molding, and provides a spring receiving reinforcement capable of providing an excellent reinforcing effect and excellent urethane moldability. It is intended to provide materials and vehicle seats.
[0009]
[Means for Solving the Problems]
The present invention employs the following configuration. That is,
1. A reinforcing material for foam molding, which is a reinforcing material having the following characteristics.
Air permeability: 400 cc / sec. / Cm 2 or less Thickness: 1.0 mm or more,
Weight variation CV value: 10% or less,
Sheet stress at 5% elongation at 65 ° C .: 0.5 to 20 N / 5 cm,
Sheet stress at 5% elongation at 100 ° C .: 0.25 to 10 N / 5 cm
2. 2. The reinforcing material for a foamed molded article according to the above-mentioned item 1, mainly comprising a long-fiber nonwoven fabric having a fiber diameter of 40 μm or less and subjected to an entanglement treatment.
3. 2. The foam molded article reinforcing material according to the above item 1, wherein the entanglement treatment is performed by a mechanical entanglement method or a hydroentanglement method.
4. 2. The reinforcing material for foam molding according to the above item 1, wherein the reinforcing material has a two-layer structure of a dense layer and a base material layer.
5. 2. The reinforcing material for foam molding according to the above item 1, wherein the reinforcing material has a three-layer structure of a base material layer, a dense layer and a base material layer.
6. The dense layer has a basis weight of 50 g / m 2 or less and an apparent density of 0.05 to 0.40 g / cm 3 , and the base layer has a basis weight of 30 g / m 2 or more and an apparent density of 0.01 to 0.1 g / m 2 . The foam molding reinforcing material according to the fourth or fifth aspect, wherein the reinforcing material is 3 g / cm 3 .
7. 6. The foam molding reinforcing material according to the fourth or fifth aspect, wherein the dense layer is a melt-blown nonwoven fabric having a fiber diameter of 10 μm or less.
8. The foam-molding reinforcing material according to the fourth or fifth aspect, wherein the dense layer is a nonwoven fabric made of a core-sheath composite fiber having a low melting point component disposed in a sheath.
9. 6. The foam-molding reinforcing material according to the fourth or fifth aspect, wherein the dense layer is a nonwoven fabric made of any one of polytrimethylene terephthalate, polybutylene terephthalate fibers, polyurethane fibers, and polyester elastomer fibers.
10. The reinforcing material for foam molding according to the fourth or fifth aspect, wherein the base material layer is a nonwoven fabric made of flame-retardant polyester fibers obtained by copolymerizing a phosphorus atom in a content of 100 to 50,000 ppm.
11. 2. The foam-molding reinforcing material according to the first aspect, wherein the foam-forming reinforcing material is disposed between a vehicle seat made of polyurethane foam and a spring material supporting the seat.
12. A vehicle seat, wherein the foam molding reinforcing material according to the first aspect is laminated on a spring material contact surface side of a vehicle seat made of polyurethane foam.
[0010]
First, the air permeability of the reinforcing material sheet is 400 cc / sec. / Cm 2 or less. 400 cc / sec. If it exceeds / cm 2 , no matter how good the moldability is, the resin will come off from the member, which will rub against the spring and generate abnormal noise. Preferably 0.1 to 400 cc / sec. / Cm 2 , more preferably 0.1 to 300 cc / sec. / Cm 2 or less.
The apparent thickness is 1.0 mm or more. If the thickness is less than 1.0 mm, the reaction of the resin will not stop in the middle of the layer but will precipitate near the surface. It is preferably 1.5 mm or more, more preferably 2.0 mm or more and 4.0 mm or less.
The variation in the sheet weight is 10% or less in CV (variation value). If it exceeds 10%, resin leakage occurs due to unevenness. Preferably it is 0.1 to 10%, more preferably 0.1 to 5%.
[0011]
A cold-type urethane foaming machine for producing a urethane sheet used in a luxury car often foams at around 65 ° C. In that case, a sheet stress of 0.5 to 20 N / 5 cm at 5% elongation at 65 ° C. is suitable. When the sheet stress exceeds 20 N / 5 cm, resin leakage and wrinkles on the surface of the reinforcing material are generated at the curved portion, particularly in deep drawing foaming. It is preferably 10 N / 5 cm or less, more preferably 0.5 to 5 N / 5 cm.
Hot type urethane foaming machines for producing urethane sheets used in low-grade vehicles often foam at around 100 ° C. In this case, the sheet stress at 5% elongation at 100 ° C. is 0.5 to 10 N / 5 cm. If the sheet stress exceeds 10 N / 5 cm, resin leakage to the surface of the reinforcing material and wrinkles occur at the curved portion, particularly in deep drawing foaming. It is preferably 5 N / 5 cm or less, more preferably 0.25-3 N / 5 cm.
[0012]
It is preferable that the dense reinforcing material has a two-layer or three-layer structure of a dense layer and a base material layer. If only a single layer is used, the basis weight non-uniformity is large, and a large amount of resin comes off. In addition, since the spring is a single layer, there is a high possibility that the spring contacts the urethane layer, and abnormal noise is generated. The urethane is stopped on the surface by the dense layer, and the abnormal noise of the rubbing of the spring is prevented by the base material layer.
In the case of the three-layer type, the dense layer serves as an intermediate layer, resin escape is stopped in the intermediate layer, and the upper and lower layers exhibit bulkiness to prevent the noise of rubbing caused by veneers.
The basis weight of the dense layer is 40 g / m 2 or less. If it exceeds 40 g / m 2 , the moldability will be poor, and resin will fall out in a deep drawing type molding machine. Preferably 30 g / m 2 or less, more preferably basis weight 15 to 20 g / m 2.
[0013]
Apparent density is 0.05~0.50g / cm 3. When the apparent density is 0.05 g / cm 3 or less, resin detachment occurs. When the apparent density is 0.50 g / cm 3 or more, the moldability is deteriorated, and particularly in the case of the deep drawing type, resin escape occurs. Preferably it is 0.1-0.4 g / cm < 3 >, More preferably, it is 0.2-0.3 g / cm < 3 >.
The basis weight of the base material layer is 30 g / m 2 or more. When it is less than 30 g / m 2 , the distance from the urethane layer stopped by the dense layer becomes short, and abnormal noise due to a spring occurs. Preferably it is 50 g / m 2 or more and 100 g / m 2 or less.
Apparent density is 0.01 to 0.3 g / cm 3. When the apparent density is less than 0.01 g / cm 3 , the chance of the spring directly contacting the urethane layer fixed to the dense layer increases, and abnormal noise due to rubbing noise is generated. If it exceeds 0.3 g / cm 3 , the moldability will be impaired.
[0014]
The fiber diameter of the dense layer is 0.1 to 40μ. If it exceeds 40 μm, urethane cannot be stopped at the surface of the dense layer and resin leakage occurs. Preferably it is 40 μm or less, more preferably 0.1 to 20 μm. Alternatively, a melt blown nonwoven fabric having a fiber diameter of 10 μm or less is also preferable.
[0015]
The member used for the dense layer can be both spunbond nonwoven fabric and short fiber nonwoven fabric. The fibers used are polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyester elastomer (PEL), polypropylene (PP), olefin-based elastomer, polyethylene (PET) PE), natural fibers such as nylon, vinylon, vinylidene chloride, rayon, cotton, etc., core / sheath structured fibers containing a low melting point component (two or more components) PET / PE, PET / low melting point isophthalic acid copolymer PET, PET / It is a mixed fiber containing PP having a low melting point metallocene catalyst, PET / PEL, PP / PP having a low melting point metallocene catalyst, or a low melting point component. Preferred are PP and PET spunbonds, more preferred are polytrimethylene terephthalate, polybutylene terephthalate fibers, polyurethane fibers, or polyester elastomers. More preferred is a core / sheath structured fiber spunbond nonwoven fabric containing a low melting point component (two or more components).
As the member used for the base material layer, both spunbond nonwoven fabric and short fiber nonwoven fabric can be used for spunbond nonwoven fabric. The fibers used are natural fibers such as PET, PBT, PTT, PEL, PP, olefin-based elastomer, PE, nylon, vinylon, vinylidene chloride, rayon and cotton. Preferably, it is a polytrimethylene terephthalate, a polybutylene terephthalate fiber, a polyurethane fiber, or a polyester elastomer nonwoven fabric. More preferably, it is PET non-woven cloth.
[0016]
Further, the base material layer is a nonwoven fabric made of flame-retardant polyester fibers obtained by copolymerizing a phosphorus atom in a content of 100 to 50,000 ppm. If the phosphorus atom is less than 100 ppm, the FMVSS standard cannot be passed. If it is more than 50,000 ppm, the fiber will break due to the friction of the spring. Preferably it is 500 to 8,000 ppm.
[0017]
The reinforcing member for foam molding is disposed between a vehicle seat made of polyurethane foam and a spring member supporting the seat. Specifically, the reinforcing material is laminated on the spring material contact surface side of the vehicle seat made of polyurethane foam, prevents the generation of friction noise generated by friction between the polyurethane foam and the spring, and has a quietness, a reinforcing effect, and molding. A seat cushion material and a vehicle seat such as a vehicle seat having excellent seating characteristics and a small variation in the basis weight.
[0018]
【Example】
Hereinafter, the present invention will be described specifically with reference to Examples. However, the present invention is not limited by this. The evaluations and characteristic values of the following examples were based on the following measurement methods.
(1) Basis weight and CV value (g / m 2 ,%)
Sample size: 5 cm width × 20 cm Ten points were sampled at intervals of 5 cm in the width direction of the raw fabric, and in the length direction, the above-mentioned transverse sample pulling was performed at ten places at intervals of 1000 m. (100 points in total)
CV value = (standard deviation / average value) × 100 (%)
(2) Thickness (mm)
Measure near the center in the center length direction of the sample size. Average value of 100 points.
The load is 2 g / cm 2 (load area 4 cm 2 )
(3) Apparent density (g / cm 3 )
Weight (g / m 2 ) / (thickness (cm) x 100 x 100)
(4) Heat strength (ST5) (N / 5cm)
Using a heating tensilon machine, a distance between chucks of 10 cm and a head speed of 10 cm / min. Was evaluated.
(1) Temperature 65 ° C x 1 min. 100 ° C. × 1 min.
(2) ST5: Strength at 5% elongation (5) Air permeability (cc / cm 2 · sec)
The measurement was performed with a Frazier air permeability meter according to JIS L1096.
[0019]
(Example 1)
A non-woven fabric (upper and lower layers) in which a web having a basis weight of 40 g / m 2 of a random loop structure made of 3.3 decitex polyethylene terephthalate fiber manufactured by a spun bond method and heated and pressed by a calendering process using a hot roll at 170 ° C. A bicomponent fiber (core: polyethylene terephthalate, melting point 260 ° C., sheath: copolyester copolymerized with isophthalic acid, melting point 130 ° C.) having a core-sheath weight ratio of 2.2 decitex (1: 1) produced by the method. A web (intermediate layer) with a basis weight of 20 g / m 2 having a random loop structure was entangled and integrated using a needle punch machine to obtain a bulky laminated nonwoven fabric.
[0020]
(Example 2)
A non-woven fabric obtained by thermocompression bonding a web having a basis weight of 40 g / m 2 of a random loop structure made of 3.3 decitex polyethylene terephthalate fiber manufactured by the spun bond method by a calendering process using a hot roll at 170 ° C., and also manufactured by the spun bond method Weight of a random loop structure composed of a bicomponent fiber (core: polyethylene terephthalate, melting point: 260 ° C., sheath: polypropylene copolymer, melting point: 180 ° C.) having a core / sheath weight ratio of 2.2 decitex (1: 1) / 20 g / the Webb m 2, and integrally intertwined with needle punching machine to obtain a bulky layered structure nonwoven fabric.
[0021]
(Example 3)
A non-woven fabric obtained by thermocompression bonding a web having a basis weight of 40 g / m 2 of a random loop structure made of 3.3 decitex polyethylene terephthalate fiber manufactured by the spun bond method by a calendering process using a hot roll at 170 ° C., and also manufactured by the spun bond method The obtained web having a basis weight of 40 g / m 2 of a random loop structure composed of polyethylene terephthalate fibers of 2.2 decitex was entangled and integrated using a needle punch machine to obtain a bulky laminated nonwoven fabric.
[0022]
(Example 4)
A non-woven fabric obtained by heating and pressing a web having a basis weight of 40 g / m 2 of a random loop structure composed of 3.3 decitex polyethylene terephthalate fibers manufactured by a spun bond method by calendering using a hot roll at 170 ° C., and a melt blow method. A web having a basis weight of 20 g / m 2 made of 0.1 decitex polypropylene nonwoven fabric was entangled and integrated using a needle punch machine to obtain a bulky laminated nonwoven fabric.
[0023]
(Example 5)
A web having a basis weight of 100 g / m 2 and a random loop structure composed of 2.2 decitex polybutylene terephthalate fiber manufactured by a spun bond method is heat-pressed by calendering with a hot roll at 150 ° C., and entangled using a needle punch machine. A nonwoven fabric was obtained by expressing bulkiness.
[0024]
(Example 6)
A nonwoven fabric (upper and lower layers) obtained by heating and pressing a web having a basis weight of 40 g / m 2 of a random loop structure made of 3.3 dtex polytrimethylene terephthalate fiber manufactured by a spun bond method by calendering with a hot roll at 150 ° C. A web having a basis weight of 20 g / m 2 of a random loop structure composed of 2.2 decitex polytrimethylene terephthalate fiber, also manufactured by the spunbond method, was integrated with three layers of entanglement using a needle punch machine to obtain a bulky laminated structure nonwoven fabric. Was.
[0025]
(Example 7)
A nonwoven fabric (upper and lower layers) obtained by heating and pressing a web having a basis weight of 40 g / m 2 of a random loop structure made of 2.2 decitex polybutylene terephthalate fiber manufactured by a spunbond method by calendering using a 150 ° C. hot roll, A web having a basis weight of 20 g / m 2 and a random loop structure made of 2.2 decitex polyethylene terephthalate fiber, also manufactured by the spunbond method, was integrated into three entangled layers using a needle punch machine to obtain a bulky laminated nonwoven fabric.
[0026]
(Comparative Example 1)
A non-woven fabric obtained by thermocompression bonding a web having a basis weight of 80 g / m 2 having a random loop structure made of 3.3 decitex polyethylene terephthalate fiber manufactured by the spunbond method by calendering with a hot roll at 170 ° C., and also manufactured by the spunbond method A non-woven fabric obtained by heating and pressing a web having a basis weight of 40 g / m 2 of a random loop structure composed of polyethylene terephthalate fiber of 2.2 decitex by calendering with a hot roll at 200 ° C. is entangled and integrated using a needle punch machine, A laminated nonwoven fabric was obtained.
[0027]
(Comparative Example 2)
2. A nonwoven fabric obtained by thermocompression-bonding a web having a basis weight of 20 g / m 2 having a random loop structure composed of 1.7 decitex polypropylene fibers manufactured by a spunbonding method by calendering using a hot roll, and a nonwoven fabric similarly manufactured by a spunbonding method. A non-woven fabric obtained by heating and pressing a web having a basis weight of 20 g / m 2 of a 3 decitex polyethylene terephthalate fiber with a basis weight of 20 g / m 2 by calendering using a hot roll at 200 ° C. was entangled and integrated using a needle punch machine to obtain a laminated non-woven fabric. .
[0028]
(Comparative Example 3)
A nonwoven fabric obtained by thermocompression bonding a web having a basis weight of 80 g / m 2 of a random loop structure made of 3.3 decitex polyethylene terephthalate fiber manufactured by the spun bond method by a calendering process using a hot roll at 170 ° C., and also manufactured by the spun bond method A nonwoven fabric obtained by heating and pressing a web having a basis weight of 80 g / m 2 of a random loop structure made of polyethylene terephthalate fiber of 6.6 decitex by calendering with a hot roll at 200 ° C. is entangled and integrated using a needle punch machine, and laminated. A structural nonwoven was obtained.
[0029]
[Table 1]
[Table 2]
Formability: × Many wrinkles are generated in R part, Δ Wrinkles are partially generated in R part, ○ No wrinkle and R part is formed. Urethane exudation: × R part, many exudations are generated on flat surface. △ The bleeding occurs in the R part, バ ネ No bleeding is seen at all. Spring rub break: × The surface is worn up to the urethane part, △ The surface is fuzzy in some places, ○ Fuzz is scarcely observed. Unusual noise caused by spring rubbing: × Noise always sounds when riding, 音 Sound sometimes occurs only in winter, ○ Slightly no sound Reinforcement handleability: × Cannot be set in the mold, △ When it cannot be set in the mold depending on where it is held There are: ○ FMVSS flame retardancy test that can be easily set in the mold: × failed, ○ passed
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the fall of seat cushion material rigidity of a vehicle etc. is prevented, the frictional noise which generate | occur | produces due to the friction between a polyurethane foam and a spring is prevented, and the variation in the sheet weight excellent in silence, reinforcement effect, and moldability is reduced. It is possible to provide a foam molded article reinforcing material such as a small number of vehicle seats and a vehicle seat.
[Brief description of the drawings]
FIG. 1 is a schematic view showing the structure of a spring receiving member.
[Description of Symbols] A layer: base material layer (bulky layer), B layer: dense layer (molded layer), C layer: base material layer (bulky layer)
Claims (12)
通気度：４００ｃｃ／ｓｅｃ．／ｃｍ２以下
厚さ：１．０ ｍｍ以上、
目付バラツキＣＶ値：１０％以下、
６５℃時５％伸張時のシート応力：０．５〜２０Ｎ／５ｃｍ、
１００℃時５％伸張時のシート応力：０．２５〜１０Ｎ／５ｃｍA reinforcing material for foam molding, which is a reinforcing material having the following characteristics.
Air permeability: 400 cc / sec. / Cm 2 or less Thickness: 1.0 mm or more,
Weight variation CV value: 10% or less,
Sheet stress at 5% elongation at 65 ° C .: 0.5 to 20 N / 5 cm,
Sheet stress at 5% elongation at 100 ° C .: 0.25 to 10 N / 5 cm
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2003202572A JP3883008B2 (en) | 2003-03-31 | 2003-07-28 | Foam molded body reinforcement and vehicle seat |
| PCT/JP2004/010698 WO2005010262A1 (en) | 2003-07-28 | 2004-07-28 | Reinforcing material for polyurethane foam molded article, cushioning material for seat, and seat |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2003094555 | 2003-03-31 | ||
| JP2003202572A JP3883008B2 (en) | 2003-03-31 | 2003-07-28 | Foam molded body reinforcement and vehicle seat |
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| Publication Number | Publication Date |
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| JP2004353153A true JP2004353153A (en) | 2004-12-16 |
| JP3883008B2 JP3883008B2 (en) | 2007-02-21 |
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| JP2003202572A Expired - Lifetime JP3883008B2 (en) | 2003-03-31 | 2003-07-28 | Foam molded body reinforcement and vehicle seat |
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