CN114746252B - 层叠成形体及其制造方法 - Google Patents

层叠成形体及其制造方法 Download PDF

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Publication number
CN114746252B
CN114746252B CN202080080355.XA CN202080080355A CN114746252B CN 114746252 B CN114746252 B CN 114746252B CN 202080080355 A CN202080080355 A CN 202080080355A CN 114746252 B CN114746252 B CN 114746252B
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China
Prior art keywords
buffer layer
opening
laminated molded
skin
molded body
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CN202080080355.XA
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CN114746252A (zh
Inventor
赛那
东根秀治
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Midori Auto Leather Co ltd
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Midori Auto Leather Co ltd
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    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
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Abstract

本发明提供一种层叠成形体的制造方法和层叠成形体，其形成为具有柔软感的凹凸的外观，并且通过避免表面的损伤而提高美观，并且能够简单地缩短制造时间。层叠成形体的制造方法，包括：裁断工序，裁断缓冲层(第一缓冲层(11))而形成裁断部(11b)；基材层叠工序，形成第一层叠体(10A)；绝热材料载置工序，在裁断部(11b)安装绝热材料(16)；第一热压接工序，对第一层叠体(10A)进行热压接；剥离工序，将裁断部(11b)剥离(第一开口部(11c))；表皮层叠工序，形成第二层叠体(10B)；以及第二热压接工序，对第二层叠体(10B)进行热压接，将表皮(15)在开口部(第一开口部(11c))与配置于具有开口部(第一开口部(11c))的缓冲层(第一缓冲层(11))的下层的下层材料(基材(13))接合。

Description

层叠成形体及其制造方法
技术领域
本发明涉及层叠成形体及其制造方法。
背景技术
例如，作为汽车等的内饰材料所使用的层叠成形体，已知在其表面形成有凹凸的层叠成形体(例如，参照专利文献1、2)。
在专利文献1中公开了如下的构成：对由2片无纺布夹持的发泡聚氨酯实施绗缝加工，在其上表面接合表皮材料层，由此在层叠成形体上形成凹凸。
在专利文献2中公开了如下构成：使用形成有开口部的模板，利用模具对片层进行按压，由此在层叠成形体上形成凹凸。
现有技术文献
专利文献
专利文献1：国际公开第2018/096944号
专利文献2：美国专利第10118525号说明书
发明内容
发明所要解决的课题
然而，专利文献1所记载的发明为了在层叠成形体形成凹凸而需要绗缝加工，因此存在难以缩短层叠成形体的制造时间的问题。
此外，专利文献2所记载的发明存在如下问题：在设置有突起的缓冲层与设置有适合于该突起的形状的开口部的模板之间夹着片层进行按压，在层叠成形体上形成凹凸，因此成为具有带有棱角的直线的坚硬感的凹凸的外观，并且层叠成形体的表面有可能损伤。
因此，本发明的目的在于提供一种层叠成形体的制造方法和层叠成形体，其形成为具有柔软感的凹凸的外观，并且通过避免表面的损伤来提高美观，并且能够简单地缩短制造时间。
用于解决课题的手段
为了实现所述目的，本发明的层叠成形体的制造方法的特征在于，包括：裁断工序，以形成开口部的方式将缓冲层裁断而形成裁断部；基材层叠工序，在由所述裁断工序裁断后的所述缓冲层的下表面，隔着通过加热而具有粘接力的粘接片，配置基材，形成第一层叠体；绝热材料载置工序，在所述第一层叠体的所述裁断部安装绝热材料；第一热压接工序，对安装了所述绝热材料的所述第一层叠体进行热压接；剥离工序，从在所述第一热压接工序中被热压接的所述第一层叠体剥离所述裁断部而形成所述开口部；表皮层叠工序，在被剥离了所述裁断部的所述第一层叠体的上表面，经由通过加热而具有粘接力的粘接片，配置表皮，形成第二层叠体；以及第二热压接工序，将所述第二层叠体热压接，将所述表皮在所述开口部与配置于具有所述开口部的所述缓冲层的下层的下层材料接合。
为了实现所述目的，本发明的层叠成形体的特征在于，具备：缓冲层；表皮，其与所述缓冲层的上表面接合；以及基材，其与所述缓冲层的下表面接合，所述缓冲层具备开口部，所述表皮在所述开口部与所述基材接合，所述缓冲层由厚度为2-15mm、密度为20-35kg/m3的聚氨酯泡沫形成。
为了实现所述目的，本发明的层叠成形体的特征在于，具备：缓冲层；表皮，其与所述缓冲层的上表面接合；以及基材，其与所述缓冲层的下表面接合，所述缓冲层具备第一缓冲层和配置于所述第一缓冲层的下表面的第二缓冲层，所述第一缓冲层以及所述第二缓冲层的至少一方具备第一开口部。
发明的效果
这样构成的本发明的层叠成形体及其制造方法形成具有柔软感的凹凸的外观，并且通过避免表面的损伤而提高美观，并且能够简单地缩短制造时间。
附图说明
图1是表示实施例1的座椅的立体图。
图2是表示实施例1的层叠成形体的剖视图。
图3是表示在实施例1的裁断工序中被裁断的第一缓冲层的俯视图。
图4是说明实施例1的基材安装工序的剖视图。
图5是说明实施例1的绝热材料载置工序的剖视图。
图6是表示在实施例1的绝热材料载置工序中使用的绝热材料的俯视图。
图7是说明实施例1的第一热压接工序的剖视图。
图8是说明实施例1的剥离工序的说明图。
图9是表示在实施例1的剥离工序中裁断部被剥离的第一层叠体的俯视图。
图10是说明实施例1的表皮层叠工序的剖视图。
图11是说明实施例1的第二热压接工序的剖视图。
图12是表示实施例2的层叠成形体的排列的剖视图。
图13是表示实施例2的层叠成形体的剖视图。
图14是概略地表示实施例3的层叠成形体的排列的剖视图。
图15是概略地表示实施例3的层叠成形体的剖视图。
图16是概略地表示实施例4的层叠成形体的排列的剖视图。
图17是概略地表示实施例4的层叠成形体的剖视图。
图18是表示另一实施例的缓冲层的立体图。
图19是表示另一实施例的缓冲层的俯视图。
具体实施方式
以下，基于附图所示的实施例1-4对实现本发明的层叠成形体及其制造方法的实施方式进行说明。
实施例1
实施例1中的层叠成形体适用于车辆的座椅。
[座椅的构成]
图1是表示实施例1的座椅的立体图。以下，对实施例1的座椅的构成进行说明。
如图1所示，座椅1具备支承乘坐人员的臀部的座部2和支承乘坐人员的背面的背面部3。
在座部2的车辆宽度方向的中央部分和背面部3的车辆宽度方向的中央部分使用层叠成形体10。另外，层叠成形体10可以用于座部2的周缘部，也可以用于背面部的周缘部。
[层叠成形体的构成]
图2是表示实施例1的层叠成形体10的剖视图。以下，对实施例1的层叠成形体10的构成进行说明。
如图2所示，层叠成形体10具备：作为缓冲层的第一缓冲层11；在第一缓冲层11的上表面隔着作为粘接层12的第二粘接层12b配置的表皮15；以及在第一缓冲层11的下表面隔着作为粘接层12的第一粘接层12a配置的基材13。
第一缓冲层11例如可以制成厚度为2-15[mm]左右、密度为20-15[kg/m3]的聚氨酯泡沫。第一缓冲层11具有主体部11a和作为开口部的第一开口部11c。
第一开口部11c形成为在第一缓冲层11的厚度方向上贯通的开口。第一开口部11c的宽度可以设为第一缓冲层11的厚度的70％以上。例如，在第一缓冲层11的厚度为5mm的情况下，第一开口部11c的宽度可以设为7mm。此外，在第一缓冲层11的厚度为10mm的情况下，第一开口部11c的宽度可以设为10mm。
表皮15例如可以为真皮。表皮15的厚度例如可以设为1-1.4[mm]左右。另外，表皮15也可以是合成皮革、人造皮革、PVC(polyvinylchloride：聚氯乙烯)、布等。在表皮15形成有沿表皮15的厚度方向贯通的多个贯通孔15a。
基材13例如可以为尼龙。另外，基材13也可以是无纺布等。基材13也可以形成为网眼状。
在第一缓冲层11的主体部11a与表皮15之间夹设有第二粘接层12b。在第一缓冲层11的主体部11a与基材13之间夹设有第一粘接层12a。在第一缓冲层11的第一开口部11c中，表皮15经由第二粘接层12b与基材13接合，由此在层叠成形体10形成凹凸。
[层叠成形体的制造方法]
图3是表示在实施例1的裁断工序中被裁断的第一缓冲层11的俯视图。图4是说明实施例1的基材安装工序的剖视图。图5是说明实施例1的绝热材料载置工序的剖视图。图6是表示在实施例1的绝热材料载置工序中使用的绝热材料的俯视图。图7是说明实施例1的第一热压接工序的剖视图。图8是说明实施例1的剥离工序的说明图。图9是表示在实施例1的剥离工序中裁断部被剥离的第一层叠体的俯视图。图10是说明实施例1的表皮层叠工序的剖视图。图11是说明实施例1的第二热压接工序的剖视图。以下，对实施例1的层叠成形体10的制造方法进行说明。
(裁断工序)
如图3所示，在裁断工序中，以形成第一开口部11c(参照图9)的方式裁断矩形的板状的第一缓冲层11，形成多个菱形的主体部11a和裁断部11b。
通过从第一缓冲层11剥离(分离)裁断部11b，在主体部11a之间形成第一开口部11c。另外，在裁断工序中，裁断部11b处于未从第一缓冲层11剥离的状态。
(基材层叠工序)
如图4所示，在基材层叠工序中，在由裁断工序裁断的第一缓冲层11的下表面，隔着作为粘接片的第一粘接片12A配置基材13，形成第一层叠体10A。即，在主体部11a和裁断部11b的下表面，隔着第一粘接片12A配置基材13，形成第一层叠体10A。
第一粘接片12A可以使用通过加热而溶解而具有粘接力的热可塑性片材，例如聚酰胺系、聚烯烃系、聚氨酯系、聚酯系的热熔粘接剂。热熔粘接剂的热溶胶溶解的温度(熔融范围)可以为90-115℃。第一粘接片12A例如可以使用网状(蜘蛛网状)的粘接片、丝网状(网眼状)的粘接片、膜状的粘接片，但从透气性的观点出发，优选丝网状或网状的粘接片。
第一粘接片12A通过加热而溶解，形成作为粘接层12的第一粘接层12a。
(绝热材料载置工序)
如图5所示，在绝热材料载置工序中，在第一层叠体10A的裁断部11b的上表面载置绝热材料16。绝热材料16例如也可以使用将与表皮15相同厚度的相同材料贴合3片左右而得到的绝热材料。
如图5及图6所示，绝热材料16在宽度方向上形成为与裁断部11b大致相同的大小。即，绝热材料16形成为包围主体部11a的形状。
(第一热压接工序)
如图7所示，在第一热压接工序中，将安装有绝热材料16的第一层叠体10A设置于模具50，进行热压接。模具50由上模51和下模52构成。上模51具有加热器功能。上模51和下模52的分割面(分型面)形成为大致平坦。在第一热压接工序中，例如在温度为120-140℃、压力为0-0.8MPa的条件下进行5-40秒左右的热压接。
若在第一热压接工序中对第一层叠体10A进行热压接，则与未安装绝热材料16的主体部11a相邻的第一粘接片12A的部分溶解，形成具有粘接力的第一粘接层12a。由此，主体部11a与基材13接合。
另一方面，与安装有绝热材料16的裁断部11b相邻的第一粘接片12A的部分通过绝热材料16不溶解，保持不发挥粘接力的第一粘接片12A的状态。由此，裁断部11b不与基材13接合。
(剥离工序)
如图8所示，在剥离工序中，从在第一热压接工序中热压接的第一层叠体10A剥离安装有绝热材料16的裁断部11b。此时，与裁断部11b相邻的第一粘接片12A也剥离。另外，与裁断部11b相邻的第一粘接片12A也可以不被剥离而残留于基材13。
由此，如图8和图9所示，在第一缓冲层11上，在主体部11a之间形成有第一开口部11c。
(表皮层叠工序)
如图10所示，在表皮层叠工序中，在剥离了裁断部11b的第一层叠体10A的上表面，隔着作为粘接片的第二粘接片12B配置表皮15，形成第二层叠体10B。第二粘接片12B通过加热而溶解而形成具有粘接力的作为粘接层12的第二粘接层12b。
(第二热压接工序)
如图11所示，在第二热压接工序中，将第二层叠体10B设置于模具50，进行热压接。在第二热压接工序中，例如在温度为140-160℃、压力为0.5-1.2MPa的条件下进行10-40秒左右的热压接。
若在第二热压接工序中对第二层叠体10B进行热压接，则与主体部11a相邻的第二粘接片12B的部分溶解而形成具有粘接力的第二粘接层12b。由此，主体部11a与表皮15接合。
此外，与第一开口部11c相邻的第二粘接片12B的部分也溶解而形成具有粘接力的第二粘接层12b。由此，如图2所示，表皮15在第一开口部11c与配置于具有第一开口部11c的第一缓冲层11的下层的作为下层材料的基材13接合。
经过这样的工序，制造层叠成形体10。
[层叠成形体的作用]
以下，对实施例1的层叠成形体10的作用进行说明。实施例1的层叠成形体10的制造方法包括：裁断工序，以形成开口部(第一开口部11C)的方式裁断缓冲层(第一缓冲层11)而形成裁断部11b；基材层叠工序，在由裁断工序裁断的缓冲层(第一缓冲层11)的下表面，隔着通过加热而具有粘接力的粘接片(第一粘接片12A)配置基材13，形成第一层叠体10A；绝热材料载置工序，在第一层叠体10A的裁断部11b安装绝热材料16；第一热压接工序，对安装有绝热材料16的第一层叠体10A进行热压接；剥离工序，从在第一热压接工序中热压接的第一层叠体10A剥离裁断部11b而形成开口部(第一开口部11c)；表皮层叠工序，在剥离了裁断部11b的第一层叠体10A的上表面，经由通过加热具有粘接力的粘接片(第二粘接片12B)配置表皮15，形成第二层叠体10B；以及第二热压接工序，对第二层叠体10B进行热压接，将表皮15在开口部(第一开口部11c)与配置于具有开口部(第一开口部11c)的缓冲层(第一缓冲层11)的下层的下层材料(基材13)接合(图2-图11)。
表皮15在开口部(第一开口部11c)与配置于具有开口部(第一开口部11c)的缓冲层(第一缓冲层11)的下层的下层材料(基材13)接合，由此能够在层叠成形体10形成凹凸。因此，能够在不损伤表皮15的表面的情况下形成具有柔软感的凹凸的层叠成形体10。因此，能够提高层叠成形体10的美观。
此外，能够在不进行在被裁断的缓冲层(第一缓冲层11)的背面涂敷粘接剂那样的麻烦的作业的情况下，制造具有凹凸的层叠成形体10。此外，能够在不进行花费作业时间的绗缝加工的情况下制造具有凹凸的层叠成形体10。因此，能够缩短层叠成形体10的制造时间。
在实施例1的层叠成形体10的制造方法中，在第二热压接工序中，使用分割面平坦的模具，开口部具有缓冲层的厚度的70％以上的宽度(图11)。
在第二热压接工序中，使用分割面平坦的模具，在将表皮与下层材料接合时，即使缓冲层被压扁而溢出到开口部，也能够防止将开口部全部堵塞。因此，在第二热压接工序中，使用分割面平坦的模具，能够将表皮牢固地接合于下层材料。
实施例1的层叠成形体10具备：缓冲层；表皮，其接合于缓冲层的上表面；以及基材，其与缓冲层的下表面接合，缓冲层具备开口部，表皮在开口部接合于基材，缓冲层由厚度为2-15mm、密度为20-35kg/m3的聚氨酯泡沫形成(图2)。
然而，在缓冲层的厚度为2-15mm且密度小于20kg/m3的聚氨酯泡沫的情况下，若表皮经由形成于缓冲层的开口部与基材接合，则存在被表皮和基材夹着的缓冲层被压扁而在表皮的表面不形成凹凸这样的问题。
另一方面，在实施例1中，由于使用缓冲层的厚度为2-15mm且缓冲层的密度为20kg/m3以上的聚氨酯泡沫，因此若表皮经由开口部与基材接合，则被表皮和基材夹着的缓冲层具有某种程度的反作用力，因此保持在稍微被压扁。因此，能够在表皮的表面形成平缓的凹凸。
此外，在缓冲层的厚度为2-15mm且密度大于35kg/m3的聚氨酯泡沫的情况下，即使表皮经由形成于缓冲层的开口部与基材接合，缓冲层也具有较大的反作用力，因此存在表皮从基材剥离而在表皮的表面不形成凹凸这样的问题。
另一方面，在实施例1中，由于使用缓冲层的厚度为2-15mm且密度为35kg/m3以下的聚氨酯泡沫，因此在表皮经由开口部与基材接合的情况下，能够降低缓冲层的反作用力，能够防止表皮从基材剥离。因此，能够在表皮的表面形成平缓的凹凸。
即，不会进行花费作业时间的绗缝加工，能够以简易的构成在表皮的表面形成平缓的凹凸，形成柔软感的外观。此外，由于不使用模板，使用分割面平坦的模具进行热压接，因此不会损伤表皮15的表面。因此，能够提高层叠成形体的美观，并且能够缩短制造时间。
实施例2
实施例2的层叠成形体在缓冲层的构成不同这点上与实施例1的层叠成形体不同。
[层叠成形体的构成]
图12是表示实施例2的层叠成形体的排列的剖视图。图13是表示实施例2的层叠成形体的剖视图。以下，对实施例2的层叠成形体的构成进行说明。另外，对于与在上述实施例中说明的内容相同或等同的部分的说明，使用相同的用语或相同的附图标记进行说明。
如图12所示，实施例2的层叠成形体110具备：作为缓冲层的第一缓冲层11；在第一缓冲层11的上表面隔着作为粘接片的第二粘接片12B配置的表皮15；在第一缓冲层11的下表面隔着作为粘接片的第一粘接片12A配置的作为缓冲层的第二缓冲层111；以及在第二缓冲层111的下表面经由作为粘接片的第三粘接片12c配置的基材13。
第一缓冲层11是与实施例1的第一缓冲层11相同的构成，具有第一开口部11c。
第二缓冲层111例如可以是矩形的板状的聚氨酯泡沫。第二缓冲层111例如可以制成厚度为2-15[mm]左右、密度为20-35[kg/m3]的聚氨酯泡沫。
也可以在表皮15形成沿表皮15的厚度方向贯通的多个贯通孔15a。多个贯通孔15a构成为填充穴。基材13也可以形成为网眼状。
这样排列的层叠成形体110设置于模具50并进行热压接，由此，如图13所示，表皮15与第一缓冲层11的主体部11a经由第二粘接层12b接合。此外，表皮15在第一缓冲层11的第一开口部11c经由第二粘接层12b与第二缓冲层111接合。第一缓冲层11和第二缓冲层111经由第一粘接层12a接合。第二缓冲层111与基材13经由第三粘接层12c接合。
[层叠成形体的作用]
以下，对实施例2的层叠成形体110的作用进行说明。实施例2的层叠成形体110具备缓冲层；表皮15，其与缓冲层的上表面接合；以及基材13，其与缓冲层的下表面接合，缓冲层具备第一缓冲层11和配置于第一缓冲层的下表面的第二缓冲层111，第一缓冲层具备第一开口部11c(图3)。
通过第一缓冲层11具备第一开口部11c，不会进行花费作业时间的绗缝加工，能够以简易的构成容易地在表皮15的表面形成凹凸。此外，通过具有第二缓冲层111，能够提高层叠成形体110的缓冲性。因此，能够以简易的构成制成具有提高了缓冲性的柔软感的凹凸的层叠成形体110。其结果，能够提高层叠成形体110的美观，并且能够缩短制造时间。
在实施例2的层叠成形体110中，表皮15在第一开口部11c与第二缓冲层111接合。
表皮15在第一开口部11c与第二缓冲层111接合，从而能够以简易的构成在表皮15的表面形成凹凸。此外，通过具有第二缓冲层111，能够提高层叠成形体110的缓冲性。因此，能够以简易的构成制成具有提高了缓冲性的凹凸的层叠成形体110。
然而，在层叠成形体形成凹凸的情况下，考虑对层叠成形体实施绗缝加工。但是，在绗缝加工中，存在需要较多的作业时间的问题。
另一方面，在实施例2的层叠成形体110中，表皮15在第一开口部11c与第二缓冲层111接合，因此能够在不进行绗缝加工的情况下在层叠成形体110形成凹凸。因此，能够缩短具有凹凸的层叠成形体110的制造时间。
此外，在进行绗缝加工的层叠成形体中，针脚附近的氨基甲酸酯被2片无纺布和针脚压缩，层叠成形体的弹性受损。特别是，在进行绗缝加工的层叠成形体中，由于在缓冲层与表皮之间夹设无纺布，因此层叠成形体的弹性受损。因此，存在损害层叠成形体的柔软的手感这样的问题。
另一方面，在实施例2的层叠成形体110中，也不进行绗缝加工，也不会使无纺布夹设在缓冲层与表皮15之间。因此，能够得到层叠成形体110的柔软的手感。
此外，对由2片无纺布夹持的缓冲层实施绗缝加工，在其上表面接合表皮的情况下，存在针脚的痕迹形成于表皮的表面的问题。
另一方面，实施例2的层叠成形体110不进行绗缝加工，因此也不会在表皮15的表面形成针脚的痕迹。因此，能够提高层叠成形体110的设计性。
此外，对由2片无纺布夹持的缓冲层实施绗缝加工，在其上表面接合表皮的情况下，由于在缓冲层与表皮之间夹设无纺布，因此存在层叠成形体的透气性不好的问题。
另一方面，在实施例2的层叠成形体110中，也不会在缓冲层与表皮15之间夹设无纺布。因此，能够提高层叠成形体110的透气性。
在实施例2的层叠成形体110中，基材13形成为网眼状。
通过将基材13形成为网眼状，能够提高层叠成形体110的透气性。
在实施例2的层叠成形体110中，表皮15形成有多个贯通孔15a。
通过在表皮15形成多个贯通孔15a，能够提高层叠成形体110的透气性。
另外，关于其他构成以及作用效果，由于与上述实施例大致相同，因此省略说明。
实施例3
实施例3的层叠成形体在缓冲层的构成不同这点上与实施例1和2的层叠成形体不同。
[层叠成形体的构成]
图14是概略地表示实施例3的层叠成形体的排列的剖视图。图15是概略地表示实施例3的层叠成形体的剖视图。以下，对实施例3的层叠成形体的构成进行说明。另外，对于与在上述实施例中说明的内容相同或等同的部分的说明，使用相同的用语或相同的附图标记进行说明。
如图14所示，实施例3的层叠成形体210具备作为缓冲层的第一缓冲层11和作为缓冲层的第二缓冲层211。
第一缓冲层11是与实施例1的第一缓冲层11相同的构成，具有第一开口部11c。
第二缓冲层211具有主体部211a和第二开口部211c。在与第二缓冲层211的厚度方向正交的宽度方向上，第一开口部11c的中心位置和第二开口部211c的中心位置形成在相同的位置。第二缓冲层211的第二开口部211c的宽度W2形成为比第一缓冲层11的第一开口部11c的宽度W1小。
第二缓冲层211的厚度可设为与第一缓冲层11的厚度大致相同的厚度(例如2-15[mm]左右)。第二缓冲层211例如可以制成厚度为2-15[mm]左右、密度为20-35[kg/m3]的聚氨酯泡沫。
这样排列的层叠成形体210设置于模具50并进行热压接，由此，如图15所示，表皮15在第一缓冲层11的第一开口部11c经由粘接层12与第二缓冲层211接合。此外，表皮15在第二缓冲层211的第二开口部211c经由粘接层12与基材13接合。
[层叠成形体的作用]
以下，对实施例3的层叠成形体210的作用进行说明。在实施例3的层叠成形体210中，第二缓冲层211在与第一开口部11c相同的位置具备比第一开口部11c的宽度小的第二开口部211c(图15)。
通过将表皮15接合于第二缓冲层211而形成的、形成于第一开口部11c的台阶、和通过表皮15接合于基材13而形成的、形成于第二开口部211c的台阶，能够形成2段的台阶。因此，能够提高层叠成形体210的设计性。
另外，关于其他构成以及作用效果，由于与上述实施例大致相同，因此省略说明。
实施例4
实施例4的层叠成形体在缓冲层的构成不同这点上与实施例1-3的层叠成形体不同。
[层叠成形体的构成]
图16是概略地表示实施例4的层叠成形体的排列的剖视图。图17是概略地表示实施例4的层叠成形体的剖视图。以下，对实施例4的层叠成形体的构成进行说明。另外，对于与在上述实施例中说明的内容相同或等同的部分的说明，使用相同的用语或相同的附图标记进行说明。
如图16所示，实施例4的层叠成形体310具备作为缓冲层的第一缓冲层11和作为缓冲层的第二缓冲层311。
第一缓冲层11是与实施例1的第一缓冲层11相同的构成，具有第一开口部11c。
第二缓冲层311的厚度可设为与第一缓冲层11的厚度大致相同的厚度(例如2-15[mm]左右)。第二缓冲层311例如可以制成厚度为2-15[mm]左右、密度为20-35[kg/m3]的聚氨酯泡沫。
第二缓冲层311具备主体部311a和在与第二缓冲层311的厚度方向正交的宽度方向上形成于与第一缓冲层11的开口部不同的位置的第二开口部311c。
第一缓冲层11的第一开口部11c的宽度W1能够成为与第二缓冲层311的第二开口部311c的宽度W3大致相同的大小。
这样排列的层叠成形体310设置于模具50并进行热压接，由此，如图17所示，表皮15在第一开口部11c经由粘接层12与第二缓冲层311接合。第一缓冲层11在第二开口部311c经由粘接层12与基材13接合。
[层叠成形体的作用]
以下，对实施例4的层叠成形体310的作用进行说明。实施例4的层叠成形体310中，第二缓冲层311在与第一开口部11c不同的位置具备第二开口部311c，表皮15在第一开口部11c与第二缓冲层311接合，且第一缓冲层11在第二开口部311c与基材13接合(图17)。
表皮15在第一开口部11c与第二缓冲层311接合，由此能够改变形成于表皮15的表面的凹凸的形状和第一缓冲层11在第二开口部311c与基材13接合而形成于表皮15的表面的凹凸的形状。因此，能够提高层叠成形体310的设计性。
另外，关于其他构成以及作用效果，由于与上述实施例大致相同，因此省略说明。
以上，基于实施例1-4对本发明的层叠成形体进行了说明。但是，关于具体的构成，并不限定于这些实施例，只要不脱离权利要求书的各权利要求的发明的主旨，则容许设计的变更、追加、各实施例的组合等。
在实施例1-4中，示出了第一缓冲层和第二缓冲层以形成菱形的主体部的方式形成开口部的例子。但是，如图18所示，开口部411c也可以是孔。此外，如图19所示，开口部511c可以是星形，也可以是圆形、四边形、三角形。
在实施例1-4中，示出了将第一缓冲层和第二缓冲层作为聚氨酯泡沫的例子。但是，第一缓冲层和第二缓冲层并不限定于该方式，可以使用聚乙烯泡沫或聚酯泡沫等树脂泡沫、无纺布。
在实施例2-4中，示出了使第一缓冲层和第二缓冲层的厚度大致相同的例子。但是，可以使第一缓冲层的厚度比第二缓冲层的厚度厚，也可以使第二缓冲层的厚度比第一缓冲层的厚度厚。由此，能够以富有变化的设计来表现层叠成形体的凹凸。
在实施例2中，示出了在第一缓冲层11形成第一开口部11c的例子。但是，第一开口部也可以形成于第二缓冲层。
在实施例3中，示出了第二开口部211c的宽度W2形成得比第一开口部11c的宽度W1小的例子。但是，第二开口部的宽度也可以形成为比第一开口部的宽度大。
在实施例4中，示出了第一缓冲层11的第一开口部11c的宽度W1为与第二缓冲层311的第二开口部311c的宽度W3大致相同的大小的例子。但是，也能够使第一缓冲层的开口部的宽度与第二缓冲层的开口部的宽度不同。由此，能够以富有变化的设计来表现层叠成形体的凹凸。
在实施例3中，示出了第一开口部11c和第二开口部211c形成在相同位置的例子。此外，在实施例4中，示出了第一开口部11c和第二开口部311c形成于不同的位置的例子。但是，第一开口部和第二开口部也可以形成为仅一部分重叠。
在实施例1-4中，示出了将本发明的层叠成形体在车辆的座椅的车辆宽度方向上应用于中央部的例子。但是，本发明的层叠成形体也能够应用于车辆的座椅的周缘部。此外，本发明的层叠成形体也能够应用于车辆的车门内饰、车辆的中央控制台、家具等。
相关申请的交叉引用
本申请基于2019年11月21日在日本专利局申请的日本特愿2019-210771来主张优先权，其全部公开完全在本说明书中引用并入。

Claims (2)

1.一种层叠成形体的制造方法，其特征在于，包括：
裁断工序，以形成开口部的方式将缓冲层裁断而形成裁断部；
基材层叠工序，在由所述裁断工序裁断后的所述缓冲层的下表面，隔着通过加热而具有粘接力的粘接片，配置基材，形成第一层叠体；
绝热材料载置工序，在所述第一层叠体的所述裁断部安装绝热材料；
第一热压接工序，对安装了所述绝热材料的所述第一层叠体进行热压接；
剥离工序，从在所述第一热压接工序中被热压接的所述第一层叠体剥离所述裁断部而形成所述开口部；
表皮层叠工序，在被剥离了所述裁断部的所述第一层叠体的上表面，经由通过加热而具有粘接力的粘接片，配置表皮，形成第二层叠体；以及
第二热压接工序，将所述第二层叠体热压接，将所述表皮在所述开口部与配置于具有所述开口部的所述缓冲层的下层的下层材料接合。
2.根据权利要求1所述的层叠成形体的制造方法，其特征在于，
在所述第二热压接工序中，使用分割面平坦的模具，
所述开口部具有所述缓冲层的厚度的70％以上的宽度。
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