Backing fabric, seat cover composite, thread manufacturing method, fabric manufacturing method and manufacturing device

Abstract

To provide a rear base fabric of a higher-quality sheet skin composite body for a vehicle.SOLUTION: There is provided a rear base fabric of a sheet skin composite body for a vehicle, which is constituted using a yarn impregnated with a chemical liquid containing a functional agent. The sheet skin composite body has a surface cloth, the rear base fabric, and an adhesive layer to bond the surface cloth and the rear base fabric. There is also provided a yarn manufacturing method, which is a manufacturing method of a yarn having functionality and has a step to prepare a yarn, a step to impregnate the yarn with the chemical liquid containing a predetermined functional chemical agent, and a step to take the yarn out from the chemical liquid. There is further provided a manufacturing device, which has a conveyance section 10 to convey the yarn, an impregnation section 220 to impregnate the yarn with the chemical liquid containing the predetermined functional chemical agent, and a take-out section 230 to take the yarn out from the chemical liquid.SELECTED DRAWING: Figure 4B

Description

[Technical field]

[0001] The present invention relates to a backing fabric, a seat covering composite, a method for manufacturing a thread, and a method and apparatus for manufacturing a fabric. [Background technology]

[0002] Patent Document 1 discloses a vehicle seat having a backing fabric. Patent Document 2 discloses a vehicle seat surface material having a deodorizing function. [Prior art document] [Patent documents] Patent Document 1: JP 2017-169691 A Patent Document 2: JP 2000-301639 A

[0003] To provide a higher quality backing fabric for a seat covering composite for a vehicle. Summary of the Invention

[0004] A first aspect of the present invention provides a backing fabric for a vehicle seat covering composite, the backing fabric being made using yarn impregnated with a chemical solution containing a functional agent.

[0005] In the backing fabric, the functional agent may include at least one of an acetaldehyde adsorbent, an ammonia adsorbent, a water repellent, an antibacterial agent, a flame retardant, or a flame retardant.

[0006] In any of the above backing fabrics, the functional agent may include an adsorbent for acetaldehyde. The reduction rate of acetaldehyde may be 92% or more when measured by a method specified in the SEK Mark textile product certification standard.

[0007] In any of the above backing fabrics, the chemical solution may contain a binder for binding the functional drug.

[0008] In any one of the above backing fabrics, the density of the backing fabric is 10 g / m 2 More than 50g / m2 It may be the following:

[0009] In a second aspect of the present invention, there is provided a seat covering composite comprising a surface fabric, any one of the above-mentioned backing fabrics, and an adhesive layer that bonds the surface fabric and the backing fabric.

[0010] In a third aspect of the present invention, there is provided a method for manufacturing a functional thread, comprising the steps of preparing a thread, immersing the thread in a chemical solution containing a predetermined functional agent, and removing the thread from the chemical solution.

[0011] In a fourth aspect of the present invention, there is provided a method for producing a fabric, comprising the step of producing a fabric using yarn produced by the above-mentioned method for producing yarn.

[0012] In a fifth aspect of the present invention, there is provided a manufacturing apparatus comprising a transport section for transporting a thread, an immersion section for immersing the thread in a chemical solution containing a predetermined functional drug, and a removal section for removing the thread from the chemical solution.

[0013] In the manufacturing apparatus, the removal section may have a first removal section for removing a portion of the functional agent attached to the thread.

[0014] In any of the manufacturing devices described above, the first removal unit may have a mangle for squeezing the thread to remove a portion of the functional agent attached to the thread.

[0015] In any of the manufacturing devices described above, the removal section may have a second removal section for removing a portion of the functional agent attached to the thread in a process preceding the first removal section.

[0016] Any of the manufacturing devices described above may include a drying section for drying the yarn in a process subsequent to the first removal section.

[0017] In any of the manufacturing devices described above, the drying section may be an electric drying oven for electrically heating the yarn.

[0018] The above summary of the invention does not list all of the features of the present invention. Also, subcombinations of these features may also be inventions. [Brief description of the drawings]

[0019] [Figure 1A] 1 is a schematic diagram of a cross section of a seat cover composite body 100. FIG. [Figure 1B] An example of a seat pad 300 for mounting a seat cover made of the seat cover composite body 100 is shown. [Diagram 2] This is an example of the front yarns 11 and the back yarns 12 used in the back base fabric 130. [Diagram 3] 1 shows a flowchart of a method for manufacturing a fabric 500 according to a comparative example. [Figure 4A] 1 shows an example of a flow chart for producing yarn 10. [Figure 4B] 2 shows an example of the configuration of a manufacturing apparatus 200. [Figure 4C] 2 shows an example of the configuration of a manufacturing apparatus 200. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] The present invention will be described below through embodiments of the invention, but the following embodiments do not limit the scope of the invention according to the claims. Furthermore, not all of the combinations of features described in the embodiments are necessarily essential to the solution of the invention.

[0021] FIG. 1A is a schematic diagram of a cross section of a seat cover composite 100. The seat cover composite 100 includes a surface fabric 110, an adhesive layer 120, and a backing fabric 130. The seat cover composite 100 is a composite for a seat in which a plurality of fabrics are laminated. The seat cover composite 100 of this example is used for, but is not limited to, a seat cover for covering a seat frame for a vehicle. The vehicle may include vehicles such as automobiles and trains, and may include vehicles that do not run on roads, such as airplanes.

[0022] The surface fabric 110 is a fabric used on the surface of the seat cover composite body 100. The surface fabric 110 may be a woven fabric using polyester. The surface fabric 110 may be a leather-like fabric. The surface fabric 110 is bonded to the backing fabric 130.

[0023] The adhesive layer 120 adheres the surface fabric 110 and the backing fabric 130 together, and bonds the surface fabric 110 and the backing fabric 130 together. However, the method of bonding the surface fabric 110 and the backing fabric 130 together is not limited to the method using the adhesive layer 120. The material of the adhesive layer 120 may contain polyurethane or polyester. The adhesive layer 120 may contain polyester having a different composition from the surface fabric 110 and the backing fabric 130. The thickness of the adhesive layer 120 may be 1.5 mm or more and 8 mm or less. The melting point of the adhesive layer 120 may be lower than the melting points of the surface fabric 110 and the backing fabric 130. The surface fabric 110 and the backing fabric 130 can be fused together by heating the seat cover composite 100 to melt the adhesive layer 120.

[0024] The backing fabric 130 is adhered to the back surface of the surface fabric 110. In this example, the backing fabric 130 is attached to the back surface of the surface fabric 110 using an adhesive layer 120. The backing fabric 130 may be a nonwoven fabric using polyester. The surface fabric 110 and the backing fabric 130 may be made of the same material. By making each layer of the seat cover composite 100 out of the same material, recyclability is improved. The thickness of the backing fabric 130 may be thicker than the thickness of the surface fabric 110. The thickness of the backing fabric 130 may be 0.10 mm or more and 2.00 mm or less.

[0025] The backing fabric 130 is formed using yarns 10 (not shown) that are permeated with a chemical solution 225 that contains a functional agent. The yarns 10 of the backing fabric 130 may be permeated with a chemical solution 225 that contains multiple functional agents. The chemical solution 225 will be described later. The backing fabric 130 may be formed only from functional yarns 10 that are permeated with the chemical solution 225. However, the backing fabric 130 may include both functional yarns 10 and non-functional yarns.

[0026] 1B shows an example of a seat pad 300 for mounting a seat cover made of the seat cover composite 100. The seat cover composite 100 may be cut and sewn to be used as a vehicle seat cover. Vehicle seat covers are required to have high strength, wrinkle resistance, flame retardancy, and the like.

[0027] The seat pad 300 may generate acetaldehyde from the urethane, which is the main material. By providing the back base fabric 130 with an acetaldehyde adsorption function, the acetaldehyde generated from the seat pad can be efficiently deodorized. Here, if the seat cover composite 100 has poor slipperiness, it may be difficult to attach the seat cover composite 100 to the seat pad 300. In addition, if exposed to high temperatures expected in a vehicle cabin, the fabric itself may curl, leading to deterioration of the finish and seating comfort. The seat cover composite 100 of this example can have acetaldehyde adsorption properties without impairing the slipperiness of the seat.

[0028] 2 shows an example of the front yarn 11 and the back yarn 12 used in the back base fabric 130. The back base fabric 130 is created by knitting the front yarn 11 vertically and knitting the back yarn 12 horizontally. In this example, the front yarn 11 and the back yarn 12 are arranged in a 1-in-1-out pattern, but this is not limited to this. In this example, the structure of the front yarn 11 is 10 / 01, and the structure of the back yarn 12 is 00 / 55.

[0029] The knitting structure of the backing fabric 130 may be appropriately selected depending on the degree of penetration of the functional drug, ease of curling, etc. The knitting structure of the backing fabric 130 may be a knitting structure that makes the fabric less likely to wrap around the selvedge and less likely to shrink when made into a fabric. In this way, by appropriately selecting the knitting structure of the backing fabric 130, curling is prevented and it is easy to attach it to the seat pad 300.

[0030] 3 shows a flow chart of a method for manufacturing fabric 500 according to a comparative example. In step S500, fabric 500 to which no functionality has been imparted is prepared. In step S510, fabric 500 is immersed in chemical solution 225. In step S520, fabric 500 is removed from chemical solution 225 and dried. In the comparative example, fabric 500 is immersed in chemical solution 225, so that chemical solution 225 does not penetrate into the intertwined yarn portions of the knitted fabric, resulting in poor adhesion of the chemical. If chemical solution 225 does not sufficiently penetrate fabric 500, the required amount of application cannot be achieved, and the functionality of fabric 500 deteriorates.

[0031] 4A shows an example of a flowchart for manufacturing the thread 10. The flowchart in this example is an example of, and is not limited to, a method for manufacturing the thread 10. In step S100, a raw thread 10 to which no functionality is added is prepared.

[0032] In step S110, the yarn 10 is immersed in the chemical solution 225. In this example, the yarn 10 is immersed in the chemical solution 225 in the state of being the yarn 10. This allows functionality to be added to the yarn 10. The yarn 10 may be immersed in the chemical solution 225 in a state where it is not wound on a bobbin. The yarn 10 may be immersed in a combination of multiple functional agents at once. By immersing the yarn 10 in the state of being the yarn 10, the chemical solution 225 can be immersed in the yarn 10 more uniformly than when the yarn 10 is immersed in the fabric state. This makes it easier to create a multifunctional backing fabric 130. In addition, by immersing the yarn 10 in the chemical solution 225, the backing fabric 130 is given functionality while improving its slip characteristics, making it easier to attach it to a sheet. The functionality of the backing fabric 130 may be at least one of acetaldehyde adsorption, ammonia adsorption, water repellency, antibacterial properties, flame retardancy, or flame retardancy. Whether or not the yarn 10 has been immersed can be determined in the state of the backing fabric 130 by checking the degree of penetration at the portion of the backing fabric 130 where the yarns 10 cross.

[0033] In step S120, the yarn 10 is removed from the chemical solution 225. Thereafter, the backing base fabric 130 may be manufactured using the yarn 10 to which functionality has been added. The backing base fabric 130 having functionality may be bonded to the surface fabric 110 to form the seat cover composite 100. Any backing material may be attached to the back surface of the backing base fabric 130 of the seat cover composite 100. For example, a seat pad such as polyurethane is attached to the back surface of the backing base fabric 130. The attachment of the backing material may be omitted. Even if a backing material is attached to the back surface of the backing base fabric 130, the seat cover composite 100 can be easily recycled by peeling off the backing material.

[0034] 4B shows an example of the configuration of the manufacturing apparatus 200. The manufacturing apparatus 200 includes a transport section 210, a dipping section 220, a removal section 230, and a drying section 240.

[0035] The conveying unit 210 conveys the yarn 10 to each process of the manufacturing apparatus 200 using conveying rollers or the like. The conveying unit 210 of this example conveys the yarn 10 to the soaking unit 220, the take-out unit 230, and the drying unit 240 in this order. The conveying unit 210 conveys the yarn 10 wound around the first bobbin 201 to each process of the manufacturing apparatus 200 and winds it around the second bobbin 202. The conveying unit 210 of this example has a conveying mechanism that prevents the yarns 10 from coming into contact with each other, so that the yarns 10 do not come into contact with each other and cause uneven application of the chemical solution 225.

[0036] The soaking unit 220 soaks the yarn 10 in a chemical solution 225 containing a predetermined functional agent. The soaking unit 220 may have a circulation mechanism for circulating the chemical solution 225 so as to prevent unevenness in the components of the chemical solution 225. The bath of the soaking unit 220 may store the chemical solution 225 containing multiple types of functional agents.

[0037] The removal unit 230 removes the yarn 10 from the chemical solution 225 in the soaking unit 220. The removal unit 230 may remove unnecessary chemical solution 225 attached to the yarn 10. The removal unit 230 is disposed in a process subsequent to the soaking unit 220 and prior to the drying unit 240. The removal unit 230 in this example has a first removal unit 231.

[0038] The first removal unit 231 removes a portion of the functional drug adhering to the thread 10. The first removal unit 231 may have a mangle for squeezing the thread 10 to remove a portion of the functional drug adhering to the thread 10. The mangle has a mechanism for squeezing the thread 10 by pinching it between upper and lower rolls. The first removal unit 231 can squeeze out excess drug adhering to the thread 10 to improve the permeability of the drug. Note that, although the first removal unit 231 in this example has been described as having a mangle, it may also have a configuration for removing unnecessary drug by moving the thread 10 along a plate or roll without squeezing it.

[0039] The drying section 240 dries the yarn 10 in a process following the first removal section 231. The drying section 240 of this example dries the yarn 10 immersed in the chemical solution 225 by heating the yarn 10. This makes the backing fabric 130 using the yarn 10 less likely to thermally shrink. The drying temperature by the drying section 240 may be 40°C or higher and 170°C or lower. Heating the yarn 10 in its state can reduce the time required for heating and the cost, compared to heating the backing fabric 130. In this example, drying the yarn 10 in its state can omit the process of drying the backing fabric 130.

[0040] The drying section 240 may be an electric drying oven for electrically heating the yarn 10. The drying section 240 can prevent the chemical solution 225 from falling off from the yarn 10 by heating the inside of the oven with electric heat to dry the yarn 10. This can prevent the adhered chemical from falling off due to the amount of air, as occurs when drying with hot air from a setter for drying fabric.

[0041] The functional agent of the chemical solution 225 may include at least one of an acetaldehyde adsorbent, an ammonia adsorbent, a water repellent, an antibacterial agent, a flame retardant, or a flame retardant. The functional agent of the chemical solution 225 may include an acetaldehyde adsorbent. The acetaldehyde adsorbent may include an organic amide component.

[0042] The reduction rate of acetaldehyde may be 92% or more using a method defined in the SEK Mark textile product certification standard. In this case, 92% or more of acetaldehyde gas can be reduced after 2 hours in the state of the seat skin composite 100. The reduction rate of acetaldehyde may be measured in the state of the seat skin composite 100.

[0043] The particle size of the functional agent in the chemical solution 225 may be 1 nm or more and 40 nm or less. By penetrating the chemical solution 225 with a small particle size of the functional agent into the yarn 10, the deterioration of the slipperiness can be suppressed. On the other hand, if the particle size of the functional agent is large, it may adhere to the periphery of the yarn, making it difficult to bend the yarn and causing the slipperiness to deteriorate. By improving the slipperiness of the yarn 10, it becomes easier to attach the sheet cover composite 100 to the sheet.

[0044] The chemical solution 225 may contain a binder for binding the functional drug. If the yarn 10 is immersed in the chemical solution 225, it becomes difficult to knit, but if the chemical solution 225 contains a binder, it becomes easier to form the knitting texture of the back base fabric 130.

[0045] Furthermore, by including a binder in the chemical solution 225, it becomes easier to prevent the chemical solution 225 from falling off even in the case of the backing fabric 130 having a low density. The density of the backing fabric 130 may be lower than the density of the surface fabric 110. The density of the surface fabric 110 is 250 g / m 2 More than 400g / m 2 The density of the backing fabric 130 may be 10 g / m 2 More than 50g / m 2 The back base fabric 130 of this embodiment has a low density and is lightweight, but by immersing the thread 10 in the chemical solution 225 and impregnating the chemical solution 225 with a binder, it becomes easier to prevent the chemical solution 225 from falling off. 2 It is not easy to uniformly infiltrate a functional drug into a high-density fabric, such as a fabric having a diameter larger than 1 mm, but by immersing the thread 10 in the drug solution 225, the permeability into the high-density fabric can be improved.

[0046] The chemical solution 225 may contain a silicone material, which improves the slipperiness of the thread 10 and suppresses the generation of white powder due to friction or the like.

[0047] Fig. 4C shows an example of the configuration of manufacturing apparatus 200. Manufacturing apparatus 200 of this example differs from manufacturing apparatus 200 of Fig. 4B in that removal unit 230 has second removal unit 232. In this example, the differences from manufacturing apparatus 200 of Fig. 4B will be particularly described.

[0048] The second removal unit 232 is disposed in a process preceding the first removal unit 231. The second removal unit 232 removes a portion of the functional agent attached to the thread 10. The second removal unit 232 may have a plate or a roll, and may preliminarily remove the agent by contacting the thread 10. Note that the removal unit 230 may omit the first removal unit 231 and have only the second removal unit 232.

[0049] Although the present invention has been described above using the embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments. It is clear to those skilled in the art that various modifications and improvements can be made to the above embodiments. It is clear from the description of the claims that such modifications and improvements can also be included in the technical scope of the present invention.

[0050] It should be noted that the order of execution of each process, such as operations, procedures, steps, and stages, in the devices, systems, programs, and methods shown in the claims, specifications, and drawings is not specifically stated as "before," "prior to," etc., and may be realized in any order unless the output of a previous process is used in a later process. Even if the operational flow in the claims, specifications, and drawings is explained using "first," "next," etc. for convenience, it does not mean that it is essential to perform the process in this order. [Explanation of symbols]

[0051] 10 yarn, 11 front yarn, 12 back yarn, 100 seat skin composite, 110 surface fabric, 120 adhesive layer, 130 back base fabric, 200 manufacturing device, 201 first bobbin, 202 second bobbin, 210 conveying section, 220 immersion section, 225 chemical solution, 230 removal section, 231 first removal section, 232 second removal section, 240 drying section, 300 seat pad, 500 fabric

Claims

1. A backing fabric for a vehicle seat cover composite, comprising: It is made of threads permeated with a medicinal solution containing functional drugs, The functional agent includes at least one of an acetaldehyde adsorbent, an ammonia adsorbent, a water repellent, an antibacterial agent, a flame retardant, or a flame retardant; The particle size of the functional agent is 1 nm or more and 40 nm or less.

2. The functional agent includes an adsorbent for acetaldehyde, The reduction rate of acetaldehyde is 92% or more when measured by the method specified in the SEK Mark textile product certification standard. The backing fabric according to claim 1.

3. The chemical solution contains a binder for binding the functional drug. The backing fabric according to claim 1.

4. The weight of the backing fabric is 10 g / m ２ Above, 50g / m ２ is less than or equal to The backing fabric according to claim 1.

5. Surface fabric and The backing fabric according to any one of claims 1 to 4, An adhesive layer that bonds the surface fabric and the backing fabric; A seat skin composite comprising:

6. A method for producing a functional yarn, comprising the steps of: preparing a thread; A step of immersing the yarn in a chemical solution containing a predetermined functional drug while transporting the yarn in a thread state; removing the thread from the chemical solution; Equipped with The step of removing the thread from the chemical solution includes: a first removal step of squeezing the thread using a mangle to remove a portion of the functional agent attached to the thread; A second removal step for removing a part of the functional drug attached to the thread using a plate-shaped removal part in a process prior to the first removal step; having The method for producing a yarn, wherein the functional agent includes at least one of an acetaldehyde adsorbent, an ammonia adsorbent, a water repellent, an antibacterial agent, a flame retardant, or a flame retardant.

7. The method includes the steps of: manufacturing a fabric using the yarn manufactured by the method for manufacturing the yarn according to claim 6; Fabric manufacturing method.

8. A conveying section for conveying the yarn; an immersion unit for immersing the yarn in a chemical solution containing a predetermined functional drug while transporting the yarn in a thread state; A removal unit that removes the thread from the chemical solution; Equipped with The take-out section includes: A first removal unit for removing a portion of the functional drug attached to the thread; A plate-shaped second removal unit for removing a portion of the functional drug attached to the yarn in a process prior to the first removal unit; having The first removal unit has a mangle for squeezing the thread to remove a portion of the functional drug attached to the thread, The manufacturing apparatus, wherein the functional agent includes at least one of an acetaldehyde adsorbent, an ammonia adsorbent, a water repellent, an antibacterial agent, a flame retardant, or a flame retardant.

9. A drying section is provided for drying the yarn in a process subsequent to the first removing section. The manufacturing apparatus according to claim 8.

10. The drying section is an electric drying oven for electrically heating the yarn. The manufacturing apparatus according to claim 9.

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