JP3048435B2 - Reinforcing material for foam molded products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforcing material for a foamed molded product, and more particularly to a foamed molded product which has sufficient rigidity and is used as a reinforcing material for a cushion material of a vehicle seat. The present invention relates to a foam-molded product reinforcing material that can prevent foamed polyurethane from oozing out to the surface during molding to form a cured product, and prevent generation of abnormal noise due to friction between a polyurethane foam-cured product and a sheet holding fixture. .

[0002]

2. Description of the Related Art As cushioning materials for vehicle seats and the like,
A foam molded product such as soft foamed polyurethane is used. At the bottom of such a foamed molded product, a reinforcing material for the foamed molded product is provided, and various metal fittings and members for fixing or holding the foamed molded product are fixed via the reinforcing material. I have. For example, in the case of a vehicle seat, the seat is effectively received a pressing force from a metal spring attached to a bottom portion in order to impart elasticity to the seat, so that the seat is not damaged. So that you can have
A reinforcing material for a foam molded article is stuck.

Conventionally, cold gauze, slab urethane or coarse blanket has been used as a reinforcing material for the foam molded article.
For example, a laminate of cold gauze and slab urethane or a coarse blanket obtained by laminating slab urethane via a cold gauze on the bottom surface of a foamed polyurethane molded product is used as a reinforcing material.

[0004] However, the above-mentioned conventional reinforcing material consisting of a laminated body of cold gauze and slab urethane or a coarse blanket alone does not provide sufficient rigidity. Therefore, it is necessary to dispose a metal spring to reinforce the rigidity. was there. Further, the production of a foamed polyurethane molded article having such a reinforcing material disposed on the bottom is performed in the order of first attaching the reinforcing material to the mold surface of the foaming mold, then injecting a urethane liquid and foaming. . At this time, the reinforcing material is impregnated with the urethane liquid to obtain a foamed polyurethane molded article in which the foamed cured layer obtained by foam molding and the reinforcing material are integrally joined. However, in the case of a combination of cold gauze and slab urethane, there is a problem that the air vent holes of the urethane foaming kettle are clogged with urethane liquid. In addition, in the combination of cold gauze and slab urethane, the obtained urethane foam molded article has a low rigidity. Therefore, in order to increase the rigidity, a nonwoven fabric having a two-layer structure of a high-mesh layer and a low-mesh layer is used for urethane foam molding. A reinforcing material base fabric has been proposed (Japanese Utility Model Publication No. 62-26193).

[0005]

However, in the above-mentioned reinforcing fabric base material for foam molding having a two-layer structure, it is not possible to effectively prevent the urethane resin liquid for foam molding from penetrating into the nonwoven fabric. When the urethane resin liquid that has permeated the nonwoven fabric oozes out to the surface of the reinforcing material and foams and hardens, the foamed and hardened polyurethane foam may come into contact with metal fittings such as a mounting bracket of a vehicle and generate noise due to friction. Conventionally, there has been a drawback that a coarse blanket or the like must be adhered to a portion reinforced by a metal spring or a portion to be hit by a metal fitting with an adhesive to prevent generation of abnormal noise. Furthermore, if an adhesive layer or the like is formed in the middle of the two nonwoven fabrics in order to prevent the penetration of the resin liquid, the passage of air is also prevented, so that the nonwoven fabric as a reinforcing material is not impregnated with the resin liquid. There was a problem that the function as a reinforcing material was reduced. In addition, the above-described two-layered foam base material for foam molding has a drawback that since the basis weight is low, the urethane liquid impregnation amount is small and the surface rigidity cannot be sufficiently increased.

Accordingly, an object of the present invention is to improve the rigidity of a foamed molded product by absorbing a resin liquid, to further improve workability in a foaming molding operation, and to provide a large basis weight. Because foaming molding resin liquid does not exude to the surface during molding, foamed molded products that do not generate abnormal noise due to friction between the foamed cured product generated on the surface due to oozing and holding metal fittings It is to provide a reinforcing material.

[0007]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a base material comprising a high-weight nonwoven fabric formed of fibers having a fiber diameter of 3 to 20 d and having a basis weight of 100 to 800 g / m ^2. An object of the present invention is to provide a reinforcing material for a foamed molded product having a layer and a reinforcing coating material layer made of a low-weight nonwoven fabric having a basis weight of 35 to 90 g / m ² .

Further, the present invention provides, as a first embodiment,
An object of the present invention is to provide a reinforcing material for a foam molded article, wherein the reinforcing coating material layer is laminated on one surface of a base material layer.

In a second aspect, the present invention is directed to a foam molded article having two of the base layers, wherein the reinforcing coating layer is disposed between the two base layers. It provides a reinforcing material.

Hereinafter, the reinforcing material for a foam molded article of the present invention will be described in detail.

In the reinforcing material for a foam molded article of the present invention, the material fibers of the high-weight nonwoven fabric serving as the base material layer are not particularly limited as long as they can constitute the nonwoven fabric. For example, polyamide (nylon), polypropylene, Polyester, high density polyethylene (HDPE), low density polyethylene (L
Synthetic fibers such as DPE), regenerated cellulose fibers such as rayon, natural fibers such as cotton yarn, and so-called sheath-core type composite fibers in which the core portion and the sheath portion are made of different fibers. Fibers may be used alone or in combination of two or more.

[0012] The fiber diameter of the material fibers of the high-weight nonwoven fabric is as follows:
It is 3 to 20d, preferably 4 to 10d, in that a nonwoven fabric having good hardness and flexibility can be obtained.

The weight per unit area of the high-weight nonwoven fabric is appropriate, and a nonwoven fabric with a large amount of impregnated polyurethane foam is obtained. Can prevent the occurrence of
100 to 800 g / m ² , preferably 100 to ² g / m ^2.
00 g / m ² .

[0014] The bulk density of the high-weight nonwoven fabric is usually 0.01 point, since the impregnation amount of urethane is in an appropriate range.
About 0.2 g / cm ³ , and 0.05 to 0.15 g
/ Cm ³ is preferable.

The nonwoven fabric with a high mesh weight may be manufactured by any method, for example, a spun bond method,
It may be manufactured by any of known methods such as a thermal bond method, a needle punch method, a water jet method, and a melt blown method. In particular, when the foam molded article is a vehicle seat, the resistance to the passage of the gas generated from the polyurethane foam is reduced to facilitate the ventilation of the gas, and the urethane liquid easily penetrates into the nonwoven fabric. In view of the following, a device manufactured by the needle punch method is desirable.

The material fibers forming the low-weight nonwoven fabric used in the reinforcing covering material layer of the reinforcing material for a foam molded article of the present invention are not particularly limited as long as they can constitute a nonwoven fabric. Examples of the material fibers include the same as those exemplified above.

The fiber diameter of the material fibers forming the low-weight nonwoven fabric is usually about 3 to 20 d, preferably 4 to 20 d.
It is about 10d.

Further, the basis weight of this low-weight nonwoven fabric is 3
5 to 90 g / m ² , preferably 40 to 60 g / m 2
²

The bulk density of the low-weight nonwoven fabric is not particularly limited, and is preferably adjusted to about 0.02 to 0.2 g / cm ³ .

The low-weight nonwoven fabric is manufactured by forming the material fibers into a nonwoven fabric according to a conventional method such as a spun bond method, a thermal bond method, a water jet method, a melt blow method, a needle punch method, or an embossing method. It can be carried out. In particular, when formed by embossing, the rigidity of the obtained low-weight nonwoven fabric is improved, the attachment to a mold is facilitated, and the passage of a urethane liquid is preferable. When manufacturing a low-weight nonwoven fabric by embossing, the emboss area ratio of the obtained low-weight nonwoven fabric is usually about 3 to 50%, preferably 10 to 2%.
It is adjusted to about 0%.

The method for producing the reinforcing material for a foam-molded article of the present invention is not particularly limited. For example, the low-weight nonwoven fabric is formed or prepared in advance, and this is laminated on a high-weight nonwoven fabric as a base material layer. A method of mechanically joining or heating by a needle punch and fusing; preparing a dispersion by dispersing the material fibers of the low-weight nonwoven fabric in an appropriate dispersion medium, and using the dispersion to prepare a base material A method in which an integrated layer of material fibers is formed on one side of the high-weight nonwoven fabric by papermaking, and further heat-treated to thermally fuse the low-weight nonwoven fabric, which is the integrated layer of the fibers, to the surface of the high-weight nonwoven fabric (wet process). Method); depositing the material fibers by spraying the air onto a nonwoven fabric with air;
As a method of accumulating fibers by heat treatment, a method of heat-sealing a low-weight nonwoven fabric to the surface of a high-weight nonwoven fabric (dry method) and the like can be given. The heat treatment may be performed by any method such as a method of blowing hot air, a method of passing between heat sources, a method of infrared heating, a method of a heater or the like, and a method of a hot roll. Among these methods, the needle punch method is preferable because the nonwoven fabric is provided with appropriate air permeability, gas generated when urethane foams is passed through, and the penetration of the urethane liquid can be controlled.

In the reinforcing material for a foam molded article of the present invention, the reinforcing covering material layer is provided on one side of the base material layer or between two base material layers. For example, as shown in FIG. 1 described later, a structure having a structure in which a reinforcing coating material layer is laminated on the upper surface of a base material layer;
One having a three-layer structure in which a reinforcing coating material layer is interposed between two base material layers is exemplified.

Hereinafter, the first reinforcing material for a foam molded article of the present invention will be described.
And the process of manufacturing a foam molded article using the same will be described with reference to FIGS.

A reinforcing material 1 for a foam molded article shown in FIG. 1 comprises a base layer 2 made of a high-weight nonwoven fabric, and a reinforcing coating layer 3 made of a low-weight nonwoven fabric formed on the upper surface of the base layer 2. It has.

As shown in FIG. 2, the reinforcing material 1 for a foam molded article is placed in the mold 4 such that the reinforcing coating material layer 3 is in contact with the mold surface 5 of the mold 4 for foam molding. The resin liquid for foam molding is injected into the cavity to be formed. At this time, the reinforcing material 1 for a foam molded product of the present invention has high rigidity, so that it is easy to handle when attached to the mold surface of the mold, and is excellent in workability.

Next, the foam is formed by heating and pressing to form a foamed layer 7 as shown in FIG. At this time, the resin liquid for foam molding is impregnated into the high-weight nonwoven fabric as the base material layer 2,
This is also foamed at the same time, and the foamed resin enters into the overlaid nonwoven fabric to form a foamed cured layer 2a which is cured, and a foamed molded product in which the base material layer 2 of the reinforcing material and the foamed molded layer 7 are joined is obtained. .

As described above, a foam molded article having a reinforcing material on the bottom surface is obtained. At this time, the resin liquid for foam molding is impregnated into the base material layer, ie, the nonwoven fabric, but does not reach the mold surface after passing through the reinforcing coating material layer. (Not shown) is not blocked. Moreover, since the reinforcing material and the foam molding layer are bonded as described above in the nonwoven fabric which is the base material layer of the reinforcing material, the rigidity can be improved. Further, after the foam molding, the foam hardened layer 2a is not formed on the surface of the reinforcing material 1 for the foam molded article, so that the foam hardened layer 2a comes into contact with the metal fitting 8 or the metal spring 9 attached to the foam molded article. No abnormal noise is generated.

Further, the reinforcing material 11 for a foam molded product shown in FIG.
Are two base material layers 12a and 12b made of a nonwoven fabric
And a reinforcing covering material layer 13 made of a low-weight nonwoven fabric.

As shown in FIG. 5, the reinforcing material 11 is provided on the mold surface 15 of the foaming mold 14 with the lower base material layer 12a.
The foamed molded product liquid 16 is formed by placing the foamed molded product reinforcing material 11 in such a manner that the foamed molded product liquid is injected into the formed cavity, heating and pressurizing the foamed resin to form the foamed material, as shown in FIG. Thus, a foam molded product 17 having a three-layer structure of a reinforcing material 11 for a foam molded product on the bottom surface obtained by laminating the base material layer 12b on the lower base material layer 12a via the reinforcing covering material layer 13 is obtained. At this time, the resin liquid for foam molding impregnates and penetrates the base material layer 12b and the reinforcing coating material layer 13, reaches the base material layer 12a, foams and hardens, and forms the base material layer 12b, the reinforcing coating material layer 13 and the base material. The foam hardening layer 17 is formed on a part of the material layer 12a.
Further, the resin liquid for foam molding does not reach the mold surface 15 through the base layer 12a. Therefore, the air vent holes (not shown) provided in the mold surface 15 are not closed, and after the foam molding, the foam hardened layer 17 is formed on the surface 18 of the foam-molded product reinforcing material 11. Therefore, there is no occurrence of abnormal noise due to contact with the foam hardening layer 17 and the metal fitting 19 or the metal spring 20 attached to the foam molded product.

Further, the reinforcing material 11 for the foamed molded product and the foamed molded layer 16 are the same as the reinforcing material 11 for the foamed molded product and the foamed hardened layer 1.
Because of the formation of 7 and the solid joining
Excellent rigidity is obtained.

In the three-layered reinforcing material, since the urethane liquid fills the base material layer 12a, passes through the reinforcing coating material layer 13 and reaches the base material layer 12b, compared with the two-layered reinforcing material. As a result, the urethane liquid-impregnated layer is formed thick, and the rigidity is increased. When the embossed product is used for the intermediate reinforcing covering material layer, the amount of the urethane liquid passing through is restricted, so that the amount of the urethane liquid passing through the base material layer 12b is small, and the base material layer 12b The urethane liquid does not penetrate to the surface of the seat, for example, there is no contact between the seat fitting and the urethane, and the generation of abnormal noise can be reliably prevented.

[0032]

According to the reinforcing material for a foam molded article of the present invention, since the base material layer is made of a nonwoven fabric having a high weight, the air vent hole of the molding die in the foam molding operation is not blocked, and uniform foam molding can be performed. It is possible to obtain a foam molded article having improved surface rigidity.

Further, since the high-density nonwoven fabric has the above-mentioned reinforcing coating material layer on one side, the penetration of the resin liquid for foam molding is stopped halfway, the impregnation degree of the resin liquid is adjusted, and the dense foam layer is formed. And is effective in improving rigidity. Furthermore, since the nonwoven fabric has a high-weight nonwoven fabric, the rigidity is improved. With the reinforcing material of the present invention, the work of attaching the reinforcing material to the die surface of the mold becomes easy, and the workability is greatly improved.

Further, by using the reinforcing material of the present invention, it is possible to simplify the work or structure which has been conventionally required due to low rigidity. For example, in the case of an automobile seat, the rigidity is reduced. The number of wires used to provide the wires can be reduced, which is effective in simplifying the work of attaching the wires. In addition, in the conventional reinforcing material, a coarse blanket or the like is manually attached to a portion to be hit by a metal in order to prevent abnormal noise. However, this operation is not required, and drastic rationalization and cost reduction can be achieved.

The reinforcing material for a foamed molded article of the present invention can be applied to any foamed molded article. For example, it can be applied to a foamed molded article made of urethane or the like to give good rigidity. For example, the present invention can be applied to the molding of foam molded products for various uses such as vehicle seats such as automobile seats, furniture, office chairs, and beds.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view illustrating a first embodiment of a reinforcing material for a foam molded article of the present invention.

FIG. 2 is a diagram illustrating a process of manufacturing a foam molded article using the reinforcing material for the foam molded article of the first embodiment.

FIG. 3 is a schematic cross-sectional view illustrating a structure of a foam molded article using the reinforcing material for a foam molded article of the first embodiment.

FIG. 4 is a schematic sectional view illustrating a second embodiment of the reinforcing material for a foam molded article of the present invention.

FIG. 5 is a view for explaining a process of manufacturing a foam molded article using the reinforcing material for the foam molded article of the second embodiment.

FIG. 6 is a schematic cross-sectional view illustrating the structure of a foam molded product using the foam molded product reinforcing material of the second embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Reinforcement material for foam molded products 2 Base layer 3 Reinforcement coating material layer 4 Mold 5 Mold surface 6 Foam hardened layer 7 Foam molded layer 8 Mold 9 Metal spring 11 Reinforcement material for foam molded products 12a, 12b base Material layer 13 Reinforcement coating material layer 14 Mold 15 Mold surface 16 Foam molded layer 17 Foam hardened layer 18 Surface of foamed molded product reinforcing material 19 Metal fitting 20 Metal spring

──────────────────────────────────────────────────の Continuation of the front page (51) Int.Cl. ⁷ identification code FI B29L 31:58 (58) Field surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 39/00 -39/44 D04H 1/00-18/00

Claims (3)

(57) [Claims] 1. A formed a fiber having a fiber diameter 3～20D, and a substrate layer made of a high basis weight non-woven fabric which is a basis weight 100 to 800 g / m ^2, from a low basis weight non-woven fabric of basis weight 35~90g / m ² For a foam molded article having a reinforcing covering material layer comprising: 2. The reinforcing material for a foam-molded article according to claim 1, wherein said reinforcing coating material layer is laminated on one surface of a base material layer. 3. The reinforcing material for a foam-molded article according to claim 1, comprising two of said base material layers, wherein said reinforcing coating material layer is disposed between said two base material layers.