CN108698267B - 表皮一体发泡制品及其生产方法 - Google Patents

表皮一体发泡制品及其生产方法 Download PDF

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Publication number
CN108698267B
CN108698267B CN201780012752.1A CN201780012752A CN108698267B CN 108698267 B CN108698267 B CN 108698267B CN 201780012752 A CN201780012752 A CN 201780012752A CN 108698267 B CN108698267 B CN 108698267B
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layer
foamed
skin
cushion
pad
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CN108698267A (zh
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横田隆介
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Inoac Corp
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Inoac Corp
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Abstract

提供表皮一体发泡制品，包括垫(15)和覆盖垫(15)的袋状外部材料(20)。外部材料(20)具有顶层(21)和由发泡树脂制成的衬里层(22)。衬里层(22)具有闭孔结构。在衬里层(22)上，在垫(15)侧上设置具有比本体层(26)的密度高的密度的垫侧表层(27a)。对垫侧表层(27a)施加电晕处理。

Description

表皮一体发泡制品及其生产方法
技术领域
本发明涉及表皮一体发泡制品及其生产方法。
背景技术
已知将液体聚氨酯放入具有顶层和聚氨酯片的衬里层的袋状外部材料中以使聚氨酯发泡并形成垫以获得表皮一体发泡体诸如头枕等。然而，在这种生产方法中，由于聚氨酯片是开孔结构，因此在一些情况下液体聚氨酯可能渗透聚氨酯片。如果液体聚氨酯的一部分在聚氨酯片的内部固化并且在外部材料的内部形成多个小树脂片，则损害触感。
因此，将聚氨酯膜粘在聚氨酯片的内侧上，以防止液体聚氨酯渗透聚氨酯片。此外，为了防止液体聚氨酯从缝合到袋中的聚氨酯片的缝线漏出，将聚氨酯膜的密封件粘在接缝上。然而，这种方法是昂贵的。
引用列表
专利文献
[专利文献1]JP-A-2002-210271
发明内容
技术问题
因此，本发明人先前提出使用具有闭孔结构的聚乙烯片代替具有开孔结构的聚氨酯片(参考专利文献1)。由于聚乙烯片具有闭孔结构，因此液体聚氨酯不进入聚乙烯片的内部，并且不太可能发生液体聚氨酯从接缝的泄漏。
最初，本发明人已经研究了形成大块形状的聚乙烯的发泡体，然后对发泡体进行切片以获得多个发泡聚乙烯片并用发泡聚乙烯片形成衬里层。这是因为：当从大的聚乙烯发泡体切割发泡聚乙烯片时，由于切割表面适度粗糙化，因此预期在发泡聚乙烯片和用作垫的聚氨酯之间的结合强度增强。然而，作为深入研究的结果，本发明人已经发现：通过这种方法，在发泡片和用作垫的聚氨酯之间的结合强度不增加。此外，可以设想通过经受电晕处理和表面改性处理来增加在发泡片和用作垫的聚氨酯之间的结合强度。但是，如果对这种发泡片施加电晕处理，则在电晕处理期间产生的流光电晕在本体层中产生通孔。因此，当使用作垫的聚氨酯发泡时，发泡气体可能从聚乙烯片逸出到外部，并且难以获得良好的发泡体。
因此，本发明的一个目的是提供表皮一体发泡制品及其生产方法，该表皮一体发泡制品具有良好触感、垫的良好发泡状况以及在衬里层与垫之间的良好结合强度。
问题的解决方案
根据本发明的一种形态，提供一种表皮一体发泡制品，包括：
由发泡树脂制成的垫；和
袋状外部材料，所述袋状外部材料与所述垫一体化，并且所述袋状外部材料覆盖所述垫，
其中所述外部材料包括：顶层；和由发泡树脂制成的衬里层，所述衬里层与所述顶层一体化，
由发泡树脂制成的所述衬里层具有闭孔结构，
由发泡树脂制成的所述衬里层在所述垫侧上包括垫侧表层，所述垫侧表层具有比本体层的密度高的密度，并且
对所述垫侧表层施加电晕处理。
根据本发明的另一种形态，提供一种生产表皮一体发泡制品的方法，所述表皮一体发泡制品包括垫和袋状外部材料，所述垫由发泡树脂制成，所述袋状外部材料与所述垫一体化，并且所述袋状外部材料覆盖所述垫，所述方法依次包括：
用具有闭孔结构的发泡树脂形成片状衬里层，在所述片状衬里层中，在前表面和后表面中的每一个表面上形成表层，所述表层具有比本体层的密度高的密度；
使位于所述后表面上的所述表层经受电晕处理；
将顶层结合到所述衬里层的所述前表面，以获得所述外部材料；
将所述外部材料加工成袋形状，使得所述衬里层在内侧上；和
将液体发泡树脂材料注入所述袋状外部材料的内部，并使所述发泡树脂材料发泡并硬化以获得所述垫。
发明的有益效果
根据本发明，提供表皮一体发泡制品及其生产方法，该表皮一体发泡制品具有良好触感、垫的良好发泡状况以及在衬里层与垫之间的良好结合强度。
附图说明
图1A是根据本发明的第一实施例的头枕的透视图。
图1B是根据本发明的第一实施例的头枕的剖视图。
图2是头枕的局部剖视图。
图3A是发泡片的剖视图。
图3B是电晕处理后的发泡片的剖视图。
图3C是外部材料的剖视图。
图4是示出当将发泡聚氨酯材料注入到外部材料中时模具的内部的剖视图。
图5是示出在发泡聚氨酯材料发泡并硬化之后模具的内部的剖视图。
图6A是根据第二实施例的头枕的剖视图。
图6B是根据第二实施例的头枕的局部剖视图。
图7A是示出头枕的制造步骤的视图。
图7B是示出头枕的制造步骤的视图。
图7C是示出头枕的制造步骤的视图。
具体实施方式
第一实施例
在下文中，将参考图1A至图5描述第一实施例，在该第一实施例中，将本发明应用于车辆座的头枕。如图1A中所示，本实施例的头枕10(表皮一体发泡制品的示例)设有头枕主体10H和门形支柱12。该支柱12的顶部被嵌入头枕主体10H中。支柱12的腿部12A从头枕主体10H的底部突出。支柱12的腿部12A能够被固定到车辆座90的上部。
如图1B中所示，头枕主体10H具有垫15和外部材料20，该垫15由聚氨酯泡沫形成。该外部材料20被设置在垫15的外侧。外部材料20与垫15一体化。外部材料20具有将垫15覆盖的袋形状。支柱12的顶部嵌入垫15中。
如图2中所示，外部材料20具有顶层21和衬里层22。该衬里层22与顶层21经由粘合剂层23一体化。衬里层22结合到垫15。顶层21由例如织物片、合成皮革片、真皮片等形成。衬里层22由发泡片25形成，该发泡片25由具有闭孔结构的发泡聚乙烯制成。发泡片25的发泡倍率优选为10倍至50倍。粘合剂层23可以由例如粘合剂或热熔胶形成。
衬里层22一体地设有本体层26、垫侧表层27a和顶侧表层27b。该本体层26被设置在垫侧表层27a和顶侧表层27b之间。垫侧表层27a被设置在本体层26的在垫15侧上的前表面上。顶侧表层27b被设置在本体层26的顶层21侧上。在下面的描述中，在没有区别地提及垫侧表层27a和顶侧表层27b的情况下，在一些情况下它可以被称为表层27。
表层27是具有比本体层26的密度高的密度的层。表层27由膜形成，在该膜中聚集比在本体层26中形成的闭孔小的气泡，或者在发泡片25的发泡成型期间将该膜形成为树脂。闭孔结构是指发泡树脂中的气泡与相邻气泡不连续的结构。
对垫侧表层27a施加电晕处理，并且将垫15侧上的最外表面28a的润湿性设定为45[dyn/cm]或更大。优选地，将润湿性设定为60[dyn/cm]或更大。
垫侧表层27a在最外表面28a处结合到垫15。在不使用粘合剂等的情况下，将垫侧表层27a的最外表面28a直接结合到垫15的聚氨酯树脂。
对顶侧表层27b施加电晕处理，并且将顶层21侧上的最外表面28b的润湿性设定为45[dyn/cm]或更大。顶侧表层27b在最外表面28b处粘附到顶层21。顶侧表层27b的最外表面28b如上所述经由粘合剂层23粘附到顶层21。
接下来，将参考图3A至图5描述头枕10的生产方法。
首先，如图3A中所示，在前表面和后表面上形成有具有比本体层26的密度高的密度的表层27的片状发泡片25由具有闭孔结构的发泡聚乙烯形成。通过例如挤出成型能够连续地形成发泡片25。当通过将聚乙烯树脂原料发泡并硬化来形成发泡片25时，随着树脂在模具的前表面等上冷却，与模具及辊接触的发泡片25的前表面和后表面在微细气泡状态下固化，或者聚乙烯树脂发泡材料以膜形式硬化。以这种方式，能够在发泡片25的前表面和后表面上形成表层27。在以这种方式形成表层27的情况下，当发泡片25的厚度是1.5mm至3mm时，能够形成具有50μm至500μm的厚度的表层27。
发泡片25在后面的步骤中成为衬里层22。在后面的步骤中，由于在发泡片25的前表面上形成的表层成为顶侧表层27b，因此在前表面上形成的表层被称为顶侧表层27b。在后面的步骤中，由于在发泡片25的后表面上形成的表层成为垫侧表层27a，因此在后表面上形成的表层被称为垫侧表层27a。
接下来，对发泡片25施加电晕处理，使得垫侧表层27a和顶侧表层27b具有45[dyn/cm]或更大的润湿性。尽管即使在施加电晕处理时外观也略有变化，但是在图3B中，为了容易理解，经受电晕处理且润湿性改善的表层27a和27b的最外表面被示出为28a和28b。
已知的技术可用于电晕处理本身。电晕处理是一种表面改性处理。例如，当将发泡片25放置在两个板状电极之间并且在电极之间施加高电压时，经由发泡片25在两个电极之间产生流光电晕。由此产生的高能电子将发泡片25的聚合物键的主链和侧链切开以产生极性官能团。作为结果，使发泡片25的表面活化以增加润湿性。通过JIS K6768中规定的试验方法能够评估润湿性。
例如，未经受电晕处理的普通发泡聚乙烯的表面的润湿性是约36[dyn/cm]。另外，未经受电晕处理的普通发泡聚丙烯的表面的润湿性也是约36[dyn/cm]。通过调节电晕处理的时间、在电极之间施加的电压，能够使润湿性增加到预定值。
接下来，如图3C中所示，通过使用粘合剂、热熔胶等将顶层21结合到发泡片25的顶侧表层27b来获得外部材料20。通过该步骤，发泡片25成为衬里层22。由于在发泡片25的前表面上形成具有增强的润湿性的顶侧表层27b，所以粘合剂或熔融树脂令人满意地结合到发泡片25。因此，使在衬里层22和粘合剂层23之间的结合强度增加，并且获得将衬里层22和顶层21以高强度结合的外部材料20。
接下来，将外部材料20加工成袋形状，使得衬里层22在内侧上。在加工成袋形状之前，可以根据需要将外部材料20切割成多个小片20H，以将小片20H缝制成袋形状(参考图1B)。更具体地，首先，将外部材料20缝制成袋形状，使得衬里层22在外侧上。此时，待连接部的一部分不相互缝合，而是被制作成开口20A。接下来，如果使用该开口20A将袋上下颠倒，则能够获得缝线位于内侧的外部材料20。如果开口20A被形成为被设置在将垫15(参考图1B)的下表面覆盖的部分处，则不损害头枕10的外观设计。
接下来，将外部材料20和支柱12设定在模具30(参考图4)上。将外部材料20设置成使得开口20A面向上。将支柱12设置成使得腿部12A面向上，并且顶部位于袋状外部材料20的内部。作为模具30，可以使用用于表皮一体发泡成型的已知模具。例如，模具30具有可相对于固定模具31旋转的可动模具32。将盖模具33和34可旋转地设置在固定模具31和可动模具32的顶上。
接下来，使喷嘴36从开口20A前进到外部材料20中，并且从喷嘴36注入发泡聚氨酯材料35(参考图4)。
接下来，使发泡聚氨酯材料35在外部材料20中发泡并硬化，以形成垫15(参见图5)。由于外部材料20的垫侧表层27a的最外表面28a的润湿性被增强，垫15令人满意地附着到衬里层22。此时，因为在衬里层22中不使由于电晕处理引起的通孔在本体层中开口，发泡气体不太可能穿过衬里层22，并且垫15能够令人满意地发泡。当将成型产品从模具30脱模时，获得使外部材料20与垫15一体化的头枕10。
这里，将发泡聚氨酯材料35发泡并硬化的垫15具有0.025g/cm3至0.100g/cm3的泡沫密度。如果泡沫密度小于0.025g/cm3，则缓冲性受损，并且当施加载荷然后移除载荷时，垫15的复位变差。另外，如果发泡密度超过0.100g/cm3，则垫15变重。
接下来，将描述根据本实施例的头枕10及其生产方法的作用和效果。根据本实施例的头枕10(表皮一体发泡制品的一个示例)及其生产方法，衬里层22具有闭孔结构，并且垫侧表层27a被设置在垫侧上。另外，垫侧表层27a具有比本体层26的密度高的密度。该表层防止在电晕处理期间在本体层中形成通孔，从而气体和液体不太可能穿过垫侧表层27a。因此，当将作为垫15的液体发泡树脂材料注入到袋状外部材料20中时，液体发泡树脂材料不太可能经由垫侧表层27a漏出到本体层26或顶层21。作为结果，可能获得具有良好触感的表皮一体发泡制品。另外，当通过使液体发泡树脂材料发泡并硬化来形成垫15时，发泡气体不太可能通过垫侧表层27a漏出到本体层26和顶层21。作为结果，获得具有良好发泡状况的垫15。
当以这种方式设置在垫侧上的垫侧表层27a具有高密度时，液体发泡树脂材料不太可能渗透到垫侧表层27a的内部和位于垫侧表层27a的进一步内方的本体层26中，从而不能期望锚固效果。因此，担心在垫15和衬里层22之间的结合强度可能减小。另外，如上所述，由于垫侧表层27a的前表面是光滑的，因此也不发生锚固效果，并且担心在垫15和衬里层22之间的结合强度可能减小。
然而，本发明人已经根据实验发现：电晕处理能够提高垫侧表层27a的润湿性，能够防止通过电晕处理形成通孔，并且能够获得在垫15与衬里层22之间的良好结合强度。作为结果，能够确保在垫15和外部材料20之间的良好结合强度。
通常，当获得具有厚度的块状发泡材料然后在厚度方向上将发泡材料切成多个片时，能够获得不具有表层的发泡片。如果对这种发泡片施加电晕处理，则在电晕处理期间产生的流光电晕在本体层中产生通孔。以这种方式，液体或气体容易穿过表层。
另外，根据本实施例的生产方法，由于在连续形成发泡片25之后在不在厚度方向上切割发泡片25的情况下能够在后面的步骤中使用发泡片25，因此容易减小头枕10的生产成本。
另外，在上述实施例的表皮一体发泡制品中，衬里层22可以在顶层21侧的表面上一体地设有顶侧表层27b，该顶侧表层27b具有比本体层26的密度高的密度和通过电晕处理得到的45[dyn/cm]或更大的润湿性。此外，在上述实施例的表皮一体发泡制品的生产方法中，在将发泡片25形成为衬里层22的步骤之后，在通过将发泡片25结合到顶层21来获得外部材料20的步骤之前，可以执行电晕处理使得位于前表面上的表层(顶侧表层27b)的润湿性是45[dyn/cm]或更大。
除了垫侧表层27a之外，即使利用顶侧表层27b，也能够防止在顶侧上的电晕处理期间形成通孔，并且导致气体和液体难以通过衬里层22。作为结果，当将要成为垫15的液体发泡树脂材料被注入到外部材料20的内部时，能够可靠地防止发泡树脂材料渗透到顶层21中。另外，当作为垫15的发泡树脂材料在外部材料20的内部发泡并硬化时，气体更不可能漏出到外部，并且更可能获得具有良好发泡状况的垫15。
另外，在上述实施例的表皮一体发泡制品中，垫侧表层27a的润湿性可以被设定为60[dyn]或更大。润湿性被进一步提高，并且在衬里层22和垫15之间的结合强度更可能被增加。
[第二实施例]
在下文中，将参考图6A至图7C描述本发明的第二实施例。该实施例是以上第一实施例的变型，并且外部材料中的顶层的结构与在以上第一实施例中外部材料中的顶层的结构不同。具体地，如图6A和图6B中所示，在本实施例的头枕10V中，用聚氨酯板24将顶层21和衬里层22彼此结合的事实与以上第一实施例中的事实不同。由于头枕10V的其它构造与以上第一实施例的头枕10的其它构造相同，因此给出相同的附图标记来省略说明。
接下来，将描述头枕10V的生产方法。首先，类似于以上第一实施例，片状发泡片25由具有闭孔结构的发泡树脂形成，该片状发泡片25具有表层27，该表层27具有比前表面和后表面上的本体层26的密度高的密度。
接下来，对发泡片25施加电晕处理，使得前表面和后表面上的表层的润湿性变为45[dyn/cm]。在图6B、图7B和图7C中经受电晕处理的表层27a和27b的最外表面由28a和28b示出。
随后，通过框架层压法(火焰层压法)使聚氨酯板24介于顶层21和发泡片25之间以一体地结合以形成外部材料120H(参考图7C)。框架层压法是一种方法，在该方法中，用火覆盖聚氨酯板24，并且使聚氨酯板24的前表面熔化并在将熔化部分压靠顶层21和发泡片25的前表面的状态下固化，以将聚氨酯板24和顶层21或衬里层22一体化。此时，由于衬里层22的顶侧表层27b的润湿性高，所以能够提高在顶层21与衬里层22之间的结合性。
将以这种方式得到的发泡片25加工成袋形状，以获得外部材料20。将发泡聚氨酯材料35注入袋状形状的内部，并且使发泡聚氨酯材料35发泡并硬化，以获得头枕10V(参考第一实施例的图4和图5)。根据该实施例，也能够实现与第一实施例相同的效果。
[其它实施例]
本发明不限于上述实施例，并且例如，如下所述的实施例也被包括在本发明的技术范围中，并且此外，除了以下之外，能够在不偏离要旨的范围内作出各种变型。
在以上描述中，在发泡片25的前表面和后表面上形成表层27，但是可以至少在发泡片25的后表面上形成表层27。如果在发泡片25的后表面上形成垫侧表层27a，则通过在垫侧表层27a上执行电晕处理以增加与垫15的结合强度并导致气体和液体难以通过，能够获得在良好发泡状况下的垫。
尽管形成衬里层的发泡树脂和形成垫的发泡树脂可以彼此相同，但优选的是：形成垫的发泡树脂由开孔结构的树脂形成，并且形成衬里层的发泡树脂由闭孔结构树脂形成。通常，可能难以获得在不同树脂之间的良好结合强度。然而，根据本实施例的表皮一体发泡制品，由于垫侧表层具有高润湿性，即使形成衬里层的发泡树脂和形成垫的发泡树脂是不同的树脂，也能够获得良好的结合强度。在以上实施例中，尽管发泡片25由发泡聚乙烯形成，但是发泡片25可以由烯烃基发泡树脂诸如发泡聚丙烯等形成，只要发泡片25由例如具有闭孔结构的发泡树脂形成即可。
在以上实施例中，虽然本发明的“表皮一体发泡制品”是头枕10、10V，但它可以是例如扶手、座垫、座背等。
在第二实施例中，通过框架层压法形成外部材料120H，但是可以通过诸如粘合剂或热熔的结合来执行形成外部材料120H。
[示例]
制备第11至13号样品的头枕，并且通过表层的存在或不存在来评估垫的发泡状况。在表1中示出结果。
第11号样品：对以33[kg/m3]的密度在两侧上都具有表层的聚乙烯发泡片的两侧施加电晕处理。在放电量为0.8kW且进料速度为5m/min的条件下执行电晕处理。制备具有发泡片作为衬里层的外部材料，将作为垫的发泡树脂材料注入袋状外部材料的内部，并且使发泡树脂材料发泡并硬化以制备第11号样品的头枕。外部材料的顶层是织物(聚酯的织物)。对于垫的发泡状况，评估第11号样品的头枕。
第12号样品：在与第11号样品相同的条件下，在以33[kg/m3]的密度仅在垫侧上具有表层的聚乙烯发泡片的垫侧上施加电晕处理。与第11号样品类似，制备具有发泡片作为衬里层的外部材料，将作为垫的发泡树脂材料注入袋状外部材料的内部，并且使发泡树脂材料发泡并硬化，以制备第12号样品的头枕。外部材料的顶层是织物(聚酯的织物)。对于垫的发泡状况，评估第12号样品的头枕。
第13号样品：在与第11号样品相同的条件下，在不具有33[kg/m3]的密度的表层的聚乙烯发泡片的两侧上施加电晕处理。与第11号样品类似，制备具有发泡片作为衬里层的外部材料，将作为垫的发泡树脂材料注入袋状外部材料的内部，并且使发泡树脂材料发泡并硬化，以制备第13号样品的头枕。外部材料的顶层是织物(聚酯的织物)。对于垫的发泡状况，评估第13号样品的头枕。
在表1中示出获得的结果。在第11号和第12号两个样品中，垫的发泡状况都良好。此外，未确认发泡材料等的泄漏和渗出到顶层中。在第13号样品中垫的发泡状况差。观察到发泡材料渗出到顶层中。另外，由于发泡材料渗出到顶层中，使外部材料部分地硬化。从以上结果确认，如果在外部材料上设置至少垫侧表层，则可以获得在良好发泡状况下的垫。
[表1]
样品号 表层的存在或不存在 发泡状况
11 垫侧表层和顶侧表层 好
12 仅垫侧表层 好
13 无表层 不好
接下来，制备第21至24号样品的头枕，并且通过施加预定大小的力将外部材料与垫分离来评估在外部材料和垫之间的接合强度。在表2中示出结果。
第21号样品：第21号样品是与第11号样品相同的头枕。外部材料垫侧上的前表面的表面张力是45[dyn/cm]。作为分离试验的结果，垫和外部材料不容易分离。另外，当观察分离的表面时，虽然在垫和外部材料之间的界面部分地破坏，但是也确认：由于界面的高接合强度，在垫中发生破坏的部分没有界面的破坏。如上所述，确认第21号样品的头枕具有对于实际使用足够的接合强度。
第22号样品：对以32[kg/m3]的密度在两侧上都具有表层的由聚乙烯制成的发泡片的两侧施加电晕处理以形成外部材料，并且使用所获得的外部材料来制备第22号样品的头枕。在放电量为0.8kW且进料速度为5m/min的条件下执行电晕处理。外部材料的垫侧上的前表面的表面张力是48[dyn/cm]。作为分离试验的结果，确认在施加分离力的情况下外部材料不从垫分离，并且第22号样品的头枕具有对于实际使用足够的接合强度。当进一步增加分离力时，垫部分被大致破坏，并且外部材料被分离。也就是说，由于在垫和外部材料之间的界面的接合强度高，因此不太可能发生界面的破坏，并且破坏大致发生在垫中。
第23号样品：对以42[kg/m3]的密度在两侧上都具有表层的由聚乙烯制成的发泡片的两侧施加电晕处理以形成外部材料，并且使用所获得的外部材料来制备第23号样品的头枕。在放电量为0.8kW且进料速度为5m/min的条件下执行电晕处理。外部材料的垫侧上的前表面的表面张力是65[dyn/cm]。作为分离试验的结果，确认在施加分离力的情况下外部材料不从垫分离，并且第23号样品的头枕具有对于实际使用足够的接合强度。当进一步增加分离力时，仅垫部分破坏，并且外部材料被分离。也就是说，由于在垫和外部材料之间的界面的接合强度高，所以不发生界面的破坏，并且仅在垫中发生破坏。
第24号样品：在不对以33[kg/m3]的密度在两侧上都具有表层的由聚乙烯制成的发泡片施加电晕处理的情况下形成外部材料，并且使用所获得的外部材料制备第24号样品的头枕。外部材料的垫侧上的前表面的表面张力是36[dyn/cm]。作为分离试验的结果，确认外部材料的衬里层容易从垫分离，并且第24号样品的头枕具有对于实际使用不足的接合强度。当观察分离的表面时，确认：在垫和外部材料的衬里层之间的界面被破坏，并且因为界面的接合强度低，界面被破坏。认为：表面张力变得不足，并且由于没有对垫侧表层施加电晕处理，因此接合强度减小。
从以上结果确认：如果执行电晕处理使得垫侧表层的表面张力是45[dyn/cm]或更大，则能够获得足够的接合强度。另外，确认：如果执行电晕处理使得垫侧表层的表面张力是60[dyn/cm]或更大，则能够获得更优选的接合强度。
[表2]
样品号 表面张力[dyn/cm] 接合强度
21 45 好
22 48 好
23 65 好
24 36 不好
附图标记列表
10、10V 头枕(表皮一体发泡制品)
15 垫
20 外部材料
21 顶层
22 衬里层
25 发泡片
27a 垫侧表层
27b 顶侧表层
35 发泡聚氨酯材料(发泡树脂)

Claims (7)

1.一种表皮一体发泡制品，包括：
由发泡树脂制成的垫；和
袋状外部材料，所述袋状外部材料与所述垫一体化，并且所述袋状外部材料覆盖所述垫，
其中所述外部材料包括：顶层；和由发泡树脂制成的衬里层，所述衬里层与所述顶层一体化，
由发泡树脂制成的所述衬里层具有闭孔结构，
由发泡树脂制成的所述衬里层在所述垫侧上包括垫侧表层，所述垫侧表层具有比本体层的密度高的密度，并且
对所述垫侧表层施加电晕处理，
其中所述衬里层一体地包括与所述顶层侧的表面一体地设置的顶侧表层，并且所述顶侧表层具有比所述本体层的密度高的密度，并且所述顶侧表层通过电晕处理具有45dyn/cm或更大的润湿性。
2.根据权利要求1所述的表皮一体发泡制品，
其中所述垫侧表层通过所述电晕处理具有45dyn/cm或更大的润湿性，并且所述垫侧表层与所述衬里层的在所述垫侧上的表面一体地设置。
3.根据权利要求1所述的表皮一体发泡制品，
其中所述垫侧表层和所述顶侧表层中的每一个的润湿性是60dyn/cm或更大。
4.一种生产表皮一体发泡制品的方法，所述表皮一体发泡制品包括垫和袋状外部材料，所述垫由发泡树脂制成，所述袋状外部材料与所述垫一体化，并且所述袋状外部材料覆盖所述垫，所述方法依次包括：
用具有闭孔结构的发泡树脂形成片状衬里层，在所述片状衬里层中，在前表面和后表面中的每一个表面上形成表层，所述表层具有比本体层的密度高的密度；
使位于所述后表面上的所述表层经受电晕处理；
将顶层结合到所述衬里层的所述前表面，以获得所述外部材料；
将所述外部材料加工成袋形状，使得所述衬里层在内侧上；和
将液体发泡树脂材料注入所述袋状外部材料的内部，并使所述发泡树脂材料发泡并硬化以获得所述垫。
5.根据权利要求4所述的生产表皮一体发泡制品的方法，
其中执行所述电晕处理使得位于所述后表面上的所述表层的润湿性是45dyn/cm或更大。
6.根据权利要求5所述的生产表皮一体发泡制品的方法，进一步包括：
在形成所述衬里层的步骤之后且在获得所述外部材料的步骤之前，施加电晕处理使得位于所述前表面上的所述表层的润湿性是45dyn/cm或更大。
7.根据权利要求6所述的生产表皮一体发泡制品的方法，
其中执行所述电晕处理使得位于所述后表面和所述前表面中的每一个表面上的所述表层的润湿性是60dyn/cm或更大。
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