JPH0339808B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a seat cushion for use in transportation vehicles such as automobiles, railway vehicles, aircraft, ships, and other furniture, and a method for manufacturing the same.

(Prior Art) Conventionally, this type of seat cushion has a cushion pad made of polyurethane foam covered with a covering material, but the covering material of such a seat cushion, especially one with an uneven pattern, is It is formed by the method described in .

Sewing method: Cover a foam wading with a groove shape in advance, cover it with the skin, and sew it at the bottom of the groove to create a concave shape (eg, Utility Model Application No. 61-13689). This method causes sewing marks to appear on the surface of the skin, and both ends of the convex portion are likely to be rounded, making it unsatisfactory in terms of design, requiring labor, and being wasteful in terms of cost and time. Furthermore, there is a problem in that rainwater or the like can enter the interior of the seat cushion through the seam holes.

Stretching method A skin is placed over a foam wading in which a wire frame has been embedded in advance, and the portion of the skin where the grooves are to be formed is stretched onto the frame using threads (eg, Japanese Utility Model Application No. 61-31300). Also with this method,
Stretch marks appear on the surface of the skin, and both ends of the convex portion tend to sag, resulting in an unsatisfactory design, and the work is time-consuming and wasteful in terms of cost and time. Furthermore, there is a problem in that rainwater and the like enter the interior of the seat cushion through the tension thread passage holes.

Adhesive method: A skin layer, which has been press-formed into the desired uneven shape, is adhered to the surface of foam wading with grooves cut into the surface using an adhesive (e.g.
Special Publication 59-40037, Utility Model 61-79997). This method requires groove formation and press molding, which is wasteful in terms of cost and time.

Method using a high-frequency welder A groove shape is formed by welding a pattern forming electrode on a skin member consisting of a laminate of a skin, foam wadding, and a wading cover (e.g., JP-A No. 61-82778, Japanese Utility Model Application No. 82778/1983). 60−143945).
This method leaves welding marks on the surface of the skin, and both ends of the convex portion tend to sag, making it unsatisfactory in terms of design. In addition, the machines are expensive and consume a lot of power, resulting in a lot of waste in terms of cost.

Method using a hot press A pattern-forming press is used to create a groove shape on a skin member consisting of a laminate of a skin, foam wading, and a wadding cover by heat welding (eg, Utility Model Application No. 61-63996). This method also leaves welding marks on the surface of the skin, and both ends of the convex part tend to sag.
The design is insufficient. In addition, the power consumption of the machine is large, resulting in a lot of waste in terms of cost.

Method using integral foaming In order to prevent the foaming solution from impregnating the skin material such as fabric, a resin film or closed-cell foam backing is attached to the back of the skin material in accordance with the shape of the foaming mold, and the skin is Pour the foaming solution directly onto the back side of the material and form it integrally (e.g.
Tokuko Sho 61-17654). This method requires packing on the back side of the skin material, which is wasteful in terms of cost and time. If there is no packing, the foaming solution comes into direct contact with the skin material, so it is easy to impregnate and seep out onto the surface, resulting in a hard texture and an unsatisfactory design.

(Problems to be Solved by the Invention) An object of the present invention is to provide a seat cushion comprising a cushion pad made of polyurethane foam and covered with a covering material, wherein the shape of the uneven pattern etc. on the surface of the covering material is sharp. To provide a seat cushion which has a good appearance, has no R sag or processing marks on convex parts, has an excellent design feel, and is free from the risk of rainwater etc. intruding into the interior.

Another object of the present invention is to provide a method for producing such seat cushions easily and inexpensively, and by selecting the skin material constituting the upholstery material from a relatively wide range. .

(Means for Solving the Problems) The present invention is a seat cushion comprising a cushion pad made of polyurethane foam and a covering material coated thereon, the covering material being shaped. At least the seating part has a surface material made of a two-layer structure material, which is an integrated skin material and a polyurethane foam layer, and the shape of the surface material is formed by foaming the raw solution for the polyurethane foam layer to integrate it with the skin material. This was done at the same time as the development of the seat cushions.

In the seat cushion of the present invention, for example, a polyurethane foam stock solution is applied in a flat plate shape onto the base surface, the solution is foamed, and at the same time is integrated with the skin material, and at the time of the integration, it is made to match the shape of the product surface. Forming a bag-shaped facing material having at least a seating part of a facing material made of a two-layer laminated structure material obtained by pressing the facing material with a shaped pressing jig and shaping the facing material, The covering material is placed in a lower mold having a mold surface that matches the surface shape of the bag, a polyurethane foam stock solution is poured into the bag, the upper mold is closed, and the stock solution is foamed to form a cushion pad made of polyurethane foam. It is obtained by forming the pad and integrating the pad with the covering material.

In addition, the seat cushion of the present invention can be applied, for example, by applying a polyurethane foam stock solution in the form of a flat plate onto the base surface, foaming the stock solution, and simultaneously integrating it with the skin material, and shaping it at the same time. A bag-shaped facing material having at least the seating portion of the surface material made of the two-layer laminated structure material thus obtained is formed, and the bag-shaped facing material is placed on a lower mold having a mold surface that matches the surface shape of the surface material. Set it upside down, and apply an adhesive to at least the exposed back surface of the seating part, at least the part of the cushion pad made of polyurethane foam formed in a predetermined shape that is to be joined to the back surface, or both of them. Then, the cushion pad is laminated on the facing material, the upper mold is closed and pressure bonded, and then the facing material and pad are removed from the mold, and the sides of the facing material are turned over and put back together. You can get it no matter what.

In the above method, the term "substrate" refers to a flat plate, a glass belt, etc., which has a surface on which the polyurethane foam stock solution can be applied to a uniform thickness.

In the present invention, the skin material for the surface material is not particularly limited, but in addition to fabric, synthetic resin sheets such as polyvinyl chloride, polyvinylidene chloride, polyester, polyacrylonitrile, nylon, polyolefin, and polyurethane are preferred. If necessary, short thermoplastic synthetic resin fibers may be flocked to the surface of these sheets, or decorative patterns may be applied by engraving or the like. Furthermore, it may be made of suede or suede-like material.

The thickness of the polyurethane foam layer in the surface material is preferably about 2 to 30 mm, and the groove depth for the uneven pattern is preferably about 1 to 15 mm. It can be made to have an appropriate thickness depending on the application. The density is approx.
A range of 0.04 to 0.20 g/cm ² is preferred.

In the present invention, when the skin material and the foam layer are integrated in the process of making the surface material, shaping is also performed.

Examples of the shaping method include a method of pressing the skin material with a pressing jig having a shape that matches the shape of the product surface. In this case, by using a frame together with the above-mentioned presser jig, it is possible to manufacture a surface material in which a foam layer is formed only on a limited and specific part of the skin material that corresponds to the area within the frame. Furthermore, by using jigs of various shapes instead of a flat one as a holding jig, it is also possible to partially change the thickness of the foam layer to give it a curved shape, a stepped shape, etc. Furthermore, a frame with a foaming liquid return plate on the upper side can be used as the frame, and by folding the skin material on the board and foaming it so that it does not come into contact with the foaming liquid, the end surface of the skin material becomes polyurethane. Surfaces can be created that do not adhere to the foam. The return plate may be formed integrally with the frame, or may be separate from the frame.

In the present invention, if necessary, a resin film layer may be provided at the bottom of the entire surface material, or at the bottom of the surface material portion of the surface material. As the resin film, acrylic film is preferred due to its adhesiveness to other materials, but other synthetic resin films such as urethane film and latex may also be used depending on the purpose. The thickness of the film is preferably in the range of about 0.02 to 0.06 mm, and the weight is preferably in the range of about 10 to 60 g per 1 m ² , but depending on the use, it may be better to make it somewhat thicker.

In the present invention, the facing material may consist only of the above-mentioned facing material, but may also be sewn with other skin materials. In this case, the surface material is sewn so that it is present at least on the seating portion. The other skin material can be obtained from the same material as the skin material in the above-mentioned surface material (fabric, polyvinyl chloride, etc.), or from a material without an uneven pattern made in the same manner as the surface material.

(Example) Examples of the present invention will be described below with reference to the drawings.

A seat cushion 1 shown in FIG. 1 is constructed by covering a cushion pad 11 made of polyurethane foam with a covering material 12.

The facing material 12 is a bag-shaped material consisting of a facing material 13 and a fabric skin material 14.

The surface material 13 occupies the seating area, and the skin material 14 is provided around it.

The surface material 13 is an integral piece of a fabric skin material 131 and a polyurethane foam layer 132.

The surface of the surface material 13 has an uneven pattern (in this example, a grooved pattern).

This seat cushion 1 is manufactured as follows.

First, as shown in FIG. 2, a polyurethane foaming stock solution 130 is applied to a certain thickness on a flat substrate (glass belt in this example) 2 treated with fluororesin (Teflon), and the entire glass belt is heated to about 60°C. The fabric 131 as a skin material is temporarily adhered to a jig 3 made of wood or synthetic resin with the uneven pattern of the surface material reversed, and the fabric 131 is placed on a heated plate, with the fabric facing down as shown in FIG. was placed on the polyurethane foam stock solution 130 and foamed while applying a load of about 20 kg per 1 m ² from the top of the jig 3, forming a polyurethane foam layer 132 with a maximum thickness of 5.0 mm.
As a whole, width 10 x depth 10 x length 296mm
A two-layer laminated structure with a sharp groove shape of dimensions is made.

This is used as a surface material 13, and a fabric 14 as a skin material is sewn to this to form a bag-shaped surface material 12. Next, as shown in FIG. The facing material 12 is placed on the mold 4.
is set, a polyurethane foaming stock solution 10 having the composition shown in Table 1 is poured into the bag, a mold release agent is applied to the mold surface of the upper mold 5 that pairs with the lower mold 4, the mold is closed, and the polyurethane foam stock solution 10 is poured into the bag. 10 is foamed and hardened to form a cushion pad 11 of a predetermined shape, and the pad is integrated with a facing material 12.

After that, open the mold and remove it, if necessary,
A seat cushion 1 having a desired sharp groove shape is obtained by crushing.

Table 1 Polyol 60 parts, polymer polyol 40 parts Crosslinking agent 3.5 parts, foam stabilizer 1.0 parts Amine catalyst 0.7 parts, water 3.6 parts MDI/TDI (80/20) 44.8 parts NCO index = 102 Sheet shown in Figure 5 In the manufacturing method of the cushion 1, the same bag-like covering material 12 as described above is used as the covering material. Set it upside down, apply 150 g/m ² of adhesive (Penguin Cement 940, adhesive manufactured by Sunstar Giken Co., Ltd.) to the back of the seat area 8, and then apply polyurethane foam that has been pre-formed into a predetermined shape. Cushion pads 11 made of cushion pads 11 are laminated, upper mold 7 is closed, and a load of 125 kg/m ² is applied for 4 minutes at room temperature to press pads 11 and facing material 12 together. Thereafter, the mold is demolded, and the side surface portion 12' of the upholstery 12 is turned over and returned to its original state to obtain a seat cushion 1 having a sharp groove shape.

Further examples of other methods for making the facing material are as follows.

An acrylic film layer F having a thickness of 0.05 mm is created by applying an acrylic emulsion onto a Teflon-treated glass belt. A polyurethane foaming stock solution is applied to a certain thickness on top of this, the glass belt is transferred to a hotpot heated to about 60°C, and a frame 91 corresponding to the shape desired for foaming is placed on the glass belt as shown in FIG. 6b. Then, the surface of the fabric 93 is temporarily bonded to the holding jig 92 shown in FIG. Approximately per square meter
When foaming is performed while applying a load of 20 kg and both edges of the skin material are cut, a fabric 93, a foam layer P, and a film layer F are formed as shown in FIG.
It is possible to manufacture a skin material consisting of:

A foaming liquid return plate 911 is placed on the upper side of the frame in Fig. 6b.
Using the frame shown in FIG. 8 provided with
Similarly to the embodiments shown in FIG. 7 and FIG.
It is possible to produce a covering material in which the end surface 93' of the covering material 93 does not adhere to the polyurethane foam as shown in the figure.

(Effects of the Invention) According to the present invention, there is provided a seat cushion in which a cushion pad made of polyurethane foam is covered with an upholstery material, in which an uneven pattern etc. on the surface of the upholstery material appears sharply, The polyurethane foam has no R sagging or processing marks on the convex parts, has an excellent design, and has no thread seams on the surface, so there is no risk of rainwater entering the interior, and the skin material is in contact with this polyurethane foam. It is possible to provide a seat cushion whose skin material is difficult to peel off because it is firmly joined to the sheet cushion.

Further, according to the present invention, such a seat cushion can be manufactured easily and inexpensively, and furthermore, since it does not require any means such as fusing the skin material constituting the upholstery, the skin material can be manufactured relatively easily. By selecting from a wide range, the overall design of the seat cushion can be determined relatively freely.

[Brief explanation of the drawing]

The drawings show embodiments of the present invention; FIG. 1 is a sectional view of an example of the seat cushion of the present invention, and FIGS. 2 to 4 show an example of a method for manufacturing the cushion of FIG. 1. Figure 2 shows the state in which the polyurethane foam stock solution is applied onto the substrate surface and the skin material is temporarily fixed to the jig, and Figure 3 shows the state in which the polyurethane foam stock solution is foamed while being shaped using the jig. Figure 4 shows a state in which the cushion pad is integrally formed on the facing material obtained in Figure 3.
The figure shows another method of manufacturing the seat cushion of FIG. 1 using the facing material obtained in FIG. 3. Figures 6 and 7 show other examples of manufacturing methods for facing materials; Figure 6a is a slope view of the jig, Figure 6b is a slope view of the frame, and Figure 6c is Figure 6a. FIG. 3 is a diagram showing a state in which the skin material is temporarily fixed to the jig. Figures 8 to 10 show still other examples of manufacturing methods for the facing material. Figure 8 is a perspective view of a modified example of the frame in Figure 6b, and Figure 9 is a
Cross-sectional view showing the manufacturing method of the facing material using the jig shown in Figure 1.
Figure 0 is a perspective view of the finished facing material. DESCRIPTION OF SYMBOLS 1... Seat cushion for seat, 11... Cushion pad, 12... Upholstery material, 12'... Side part of upholstery material, 13... Surface material, 131... Skin material, 132... Polyurethane foam layer, 130 ……
Polyurethane foaming stock solution, 10...Polyurethane foaming stock solution, 14...Skin material, 2...Substrate, 3...Jig, 4...Lower mold, 5...Upper mold, 6...Press lower mold, 7... Press upper mold, 8...seating part.

Claims (1)

[Scope of Claims] 1. A seat cushion comprising a cushion pad made of polyurethane foam and a covering material coated thereon, the covering material comprising a shaped skin material and polyurethane foam. At least the seating portion has a surface material made of an integrated two-layer laminated structure material, and the surface material is shaped at the same time as it is integrated with the skin material by foaming the stock solution for the polyurethane foam layer. Seat cushions for seats. 2 Apply the polyurethane foam stock solution in a flat plate shape onto the base surface, make the stock solution foam, and at the same time integrate it with the skin material, and at the time of integration, press the skin material with a holding jig having a shape that matches the shape of the product surface. A bag-shaped facing material having at least the seating part a facing material made of a two-layer laminated structure material obtained by pressing and shaping, and having a mold surface that matches the surface shape of the facing material. The facing material is set in the lower mold, a polyurethane foam stock solution is injected into the bag, the upper mold is closed, and the stock solution is foamed to form a cushion pad made of polyurethane foam, and the pad is poured into the upholstery material. A method for producing a seat cushion, characterized by integrating the seat cushion with the seat cushion. 3 Apply the polyurethane foam stock solution in a flat plate shape onto the base surface, foam the stock solution, and at the same time integrate it with the skin material, and at the time of integration, press the skin material with a holding jig having a shape that matches the shape of the product surface. A bag-shaped facing material having at least the seating part a facing material made of a two-layer laminated structure material obtained by pressing and shaping, and having a mold surface that matches the surface shape of the facing material. The bag-like upholstery is set upside down on the lower mold, and of the exposed backside of the upholstery, it is to be bonded to at least the backside of the seating portion or a cushion pad made of polyurethane foam formed into a predetermined shape in advance. The cushion pad is laminated on the facing material by applying adhesive to one or both of them, and the upper mold is closed and pressure bonded. After that, the facing material and pad are removed from the mold, and the side surface of the facing material is laminated. A method for manufacturing a seat cushion, which is characterized by inverting and restoring the seat cushion.