JP2009154350A - Skin material for skin-integrated foam molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a skin material that can eject internal gas smoothly from an outer skin while preventing exudation of resin in putting foam resin in a bag-shaped skin material to carry out foam-molding. <P>SOLUTION: The skin material includes a surface material 11, a polyurethane foam bonded to the inside of the surface material 11, and a nonwoven fabric 13 bonded to the inside of the polyurethane foam 12 and having waterproof pressure of 450 mmH<SB>2</SB>O or higher, preferably 500 mmH<SB>2</SB>O or higher, further preferably 550 mmH<SB>2</SB>O or higher, air permeability of 0.1-20 cc/cm<SP>2</SP>/s, preferably 5-15 cc/cm<SP>2</SP>/s, and an average pore size of 0.1-20 μm, preferably 5-15 μm. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a skin material for skin-integrated foam molding, in which a skin material is sewed three-dimensionally, and a liquid foamed resin is injected into the interior to foam, thereby obtaining a molded body integrated with the skin material. It prevents bleeding due to the infiltration of foamed resin, and also has anti-bleeding and air permeability that can discharge bubbles and prevent the formation of burrows, especially for vehicle headrests, armrests, console boxes, etc. It is suitable for use in molding.

One of the products made by the integral skin foaming method is to sew the skin material three-dimensionally and inject a liquid foamed resin into the interior to foam and obtain a molded body integrated with the skin material. There is an armrest or the like (see Patent Document 1).
As the skin material used when molding vehicle headrests, armrests, and console boxes by such a skin-integrated foam molding method, the surface material such as woven fabric, non-woven fabric, knitted fabric, and synthetic leather is used from the viewpoint of texture and stretchability. Usually, a flexible polyurethane foam is adhered to the back of the fabric, but if a liquid foamed resin is injected after three-dimensional sewing, it penetrates into the flexible polyurethane foam and the flexible polyurethane foam hardens, or even to the surface fabric. It exudes and hardens and deteriorates the texture and appearance.

For this reason, the penetration of liquid foamed resin is prevented by adhering a polyurethane film to the back surface of the flexible polyurethane foam.
On the other hand, when a skin material to which such a polyurethane film is bonded is sewed and a liquid foam resin is injected into the inside, the gas (gas) generated during foaming remains without escaping, and when cooled, it shrinks and shrinks A so-called cavity is generated, which causes wrinkles in the skin material.

Therefore, there is a need for a skin material that can allow gas (gas) to pass through while preventing penetration of the liquid foamed resin. For example, a three-layer structure comprising a top cloth, a slab foam, and a shielding film in which minute ventilation holes are formed. There is a technique in which a laminate skin material is used so as to have both bleeding prevention and air permeability to prevent permeation. (See Patent Document 2).
JP-A-4-314507 Japanese Patent Laid-Open No. 1-228811

However, in the three-layer laminate skin material described in Patent Document 2, a polyurethane film or a vinyl chloride film is used as a shielding film, and since a fine ventilation hole is formed in these synthetic resin films, Due to the heat resistance problem, the size of the hole is likely to change due to heat resistance problems, and if the ventilation hole changes and the ventilation hole becomes large, bleeding due to the infiltration of the foamed resin tends to occur. There is a problem that gas (gas) does not escape due to insufficient properties, there is a problem that it is difficult to set the size of the minute ventilation holes, etc., and it is also difficult to manage the injection conditions of the foamed resin.
In addition, since this skin material is provided with a synthetic resin shielding film, the back surface is difficult to slip, it is difficult to sew with a sewing machine, and the needle of the sewing machine is difficult to pass.

  The present invention has been made in view of the problems of the prior art, and has an exudation preventing property capable of preventing exudation due to permeation of a liquid foamed resin, and an appropriate amount of gas (gas) generated during foaming. An object of the present invention is to provide a skin material for integral foam molding of the skin having breathability.

In order to solve the above-mentioned problems of the prior art, the skin material for integral foam molding according to claim 1 of the present invention is sewn into the outer shape of the molded body, and injects a liquid foamed resin into the interior to foam and integrate. A skin material for integral foam molding, comprising a surface fabric disposed on the outside of the molded body, a polyurethane foam adhered to the inside of the surface fabric, and an anti-bleeding property adhered to the inside of the polyurethane foam and It consists of a non-woven fabric having air permeability, and the anti-bleeding property of this non-woven fabric is a water pressure resistance of 450 mmH ₂ O or more, and the air permeability is an air permeability of 0.1 to 20 cc / cm ² / s. The pore size is 0.1 to 20 μm.
According to this skin material for integral foam molding, a skin material is composed of a surface fabric, a polyurethane foam, and a non-woven fabric having bleeding resistance and breathability, and the nonwoven fabric has a bleeding resistance of 450 mmH _{2 in} water pressure resistance. O and above, and the air permeability is 0.1-20 cc / cm ² / s in terms of air permeability, and the average pore size is 0.1-20 μm to prevent exudation due to penetration of the liquid foamed resin. In addition, the change in air permeability due to heat is prevented to ensure the air permeability of the gas at the time of foaming.
Accordingly, there is no need for a vent hole setting process or a micro-hole forming process, and the foaming resin injection conditions can be relaxed and a wrinkle-free product can be molded.

Moreover, the skin material for integral foam molding according to claim 2 of the present invention is characterized in that, in addition to the structure of claim 1, the nonwoven fabric has an average fiber diameter of 0.1 to 10 μm. It is.
According to the skin material for integral skin foaming, the required pore size and the like can be easily ensured by setting the average fiber diameter of the nonwoven fabric to 0.1 to 10 μm.

Furthermore, the skin material for integral foam molding according to claim 3 of the present invention is characterized in that, in addition to the configuration of claim 1 or 2, the basis weight of the nonwoven fabric is 30 to 70 g / m ^2. Is.
According to the skin material for integral foam molding of the skin, the basis weight of the nonwoven fabric is set to 30 to 70 g / m ² so that it does not become hard or does not cause molding defects.

Furthermore, in addition to the structure according to any one of claims 1 to 3, the skin material for skin integrated foam molding according to claim 4 of the present invention is that the nonwoven fabric is a nonwoven fabric obtained by a melt blow manufacturing method. It is a feature.
According to this skin material for integral foam molding, it is easy to obtain a nonwoven fabric with a flexible and ultrafine fiber diameter by molding the nonwoven fabric by the melt blow manufacturing method, and as a result, the effect on the texture of the surface fabric Can be reduced.

In addition to the structure according to any one of claims 1 to 4, the skin material for skin-integrated foam molding according to claim 5 of the present invention is a single layer of a nonwoven fabric comprising a thermoplastic elastomer resin. It is comprised by the multiple layer which laminated | stacked the nonwoven fabric which consists of another resin on this. The type of the thermoplastic elastomer is not particularly limited, and examples thereof include styrene, olefin, PVC, urethane, ester, and amide. Of these, styrene-based thermoplastic elastomers that can be obtained at a relatively low cost and have a fine fiber diameter by a melt blow production method are preferred.
According to the skin material for integral foam molding of the skin, the nonwoven fabric is composed of a single layer of a nonwoven fabric made of a thermoplastic elastomer resin or a plurality of layers obtained by laminating a nonwoven fabric made of another resin on the nonwoven fabric. In addition, air permeability and pore size are ensured to prevent seepage due to penetration of the liquid foamed resin, and the change in air permeability due to heat is suppressed, and the gas (gas) permeability during foaming is excellent.

Furthermore, in addition to the structure in any one of Claims 1-5, the skin material for skin integral foam molding of Claim 6 of this invention is at least one surface of the nonwoven fabric in which the said nonwoven fabric consists of thermoplastic elastomer resin, or It is characterized by being constituted by a two-layer or three-layer laminate provided with a nonwoven fabric made of polybutylene terephthalate resin on both sides.
According to the skin material for the integral foam molding of the skin, it is possible to prevent the liquid foam resin from seeping out due to the penetration of the foamed resin, and to provide a non-woven fabric made of polybutylene terephthalate resin with low surface friction. Excellent machine feedability.

According to the skin material for skin-integrated foam molding according to claim 1 of the present invention, the skin material is constituted by the skin material, the polyurethane foam, and the nonwoven fabric having a bleeding prevention property and breathability, and the nonwoven fabric is prevented from bleeding. Is set to 450 mmH ₂ O or more with a water pressure resistance, the air permeability is set to 0.1 to 20 cc / cm ² / s, and the average pore size is set to 0.1 to 20 μm. It is possible to prevent bleeding due to heat and prevent change in air permeability due to heat to ensure gas (gas) air permeability during foaming.
This eliminates the need for setting the air holes and forming the minute holes, making it easy to sew with a sewing machine, and relaxing the conditions for injecting the foamed resin, thereby forming a wrinkle-free product.

  Moreover, according to the skin material for skin integral foam molding according to claim 2 of the present invention, since the average fiber diameter of the nonwoven fabric is 0.1 to 10 μm, the necessary pore size can be easily secured, It is possible to prevent seepage due to penetration of the liquid foamed resin, and to ensure air permeability through which gas (gas) during foaming is appropriately discharged.

Furthermore, according to the skin material for integral foam molding according to claim 3 of the present invention, since the basis weight of the nonwoven fabric is 30 to 70 g / m ² , it is prevented that the nonwoven fabric becomes hard or a molding defect is caused. It is possible to prevent the liquid foamed resin from seeping out due to the permeation, and to ensure the air permeability through which the gas (gas) at the time of foaming escapes appropriately.

  Furthermore, according to the skin material for integral foam molding according to claim 4 of the present invention, since the nonwoven fabric obtained by the melt blow manufacturing method is used, it is flexible and easily controls required water resistance, air permeability, and pore size. It is possible to prevent permeation due to penetration of the liquid foamed resin, and to ensure air permeability through which gas (gas) during foaming can be appropriately discharged.

Moreover, according to the skin material for skin integral foam molding according to claim 5 of the present invention, the nonwoven fabric is a single layer of a nonwoven fabric made of a thermoplastic elastomer resin or a plurality of layers in which a nonwoven fabric made of another resin is laminated. Because it is configured, it can ensure the required water resistance, air permeability, and pore size, prevent exudation due to the penetration of liquid foam resin, and breathability that allows gas to escape properly during foaming Can be secured.
Further, by using a nonwoven fabric made of a thermoplastic elastomer resin, higher flexibility can be provided. The skin material for foam integrated molding is preferably as flexible as possible because it will easily crease (corner) on the surface if it is hard. If the basis weight of the thermoplastic elastomer at this time is 50% or more of the basis weight of the whole nonwoven fabric, it is effective.

Furthermore, according to the skin material for integral skin foaming according to claim 6 of the present invention, the nonwoven fabric is heated on at least one side or both sides of the nonwoven fabric made of thermoplastic elastomer resin by heating the nonwoven fabric made of polybutylene terephthalate resin. Because it is composed of a two-layer or three-layer laminate that is bonded together, it can reliably prevent seepage due to the penetration of liquid foamed resin, and it also has excellent heat resistance, preventing changes in breathability due to heat. Thus, it is possible to sufficiently ensure the air permeability through which the gas (gas) generated during foaming is adequately released, and further excellent in the machine feedability during sewing.
Further, by laminating a non-woven fabric made of polybutylene terephthalate resin on one surface of the non-woven fabric made of thermoplastic elastomer resin on the polyurethane foam side, the adhesive strength with the polyurethane foam can be improved. In addition, by laminating a non-woven fabric made of polybutylene terephthalate resin on one side opposite to the polyurethane foam, the slipperiness of the back of the skin material for skin integral foam molding can be improved, and the sewing work efficiency can be improved. I can do it.

Hereinafter, an embodiment of a skin material for foam integrated foam molding according to the present invention will be described in detail.
1 to 3 relate to an embodiment of a skin material for foam integrated foam molding of the present invention, FIG. 1 is a cross-sectional view, FIG. 2 is a schematic perspective view of a vehicle headrest as an example of a molded body, FIG. 3 is a schematic cross-sectional view of the molding process.

  A skin material 10 for skin foam integrated molding according to the present invention is used, for example, as a skin material 10 of a vehicle headrest 20 shown in FIGS. 2 and 3, and is three-dimensionally sewn into a shape corresponding to the outer shape of the headrest 20. Insert parts 21 such as reinforcing materials and support pillars are mounted therein, and a liquid foamed resin is injected into the internal space between the mounted insert parts 21 and the skin material 10, and the skin material 10 and the foamed resin foamed It becomes a headrest which is a product of a skin-integrated foam-molded product. The skin material 10 for skin integral foam molding of this invention may be used in a part of the skin of the skin integral foam molded article. For example, it is possible to use only the portion where the injection pressure of the liquid foamed resin is large.

  As shown in FIG. 1, such a skin material 10 for skin integral foam molding is constituted by adhering a surface fabric 11, a flexible polyurethane foam 12, and a non-woven fabric 13 having a bleeding prevention property and a breathability. be able to.

  As the front fabric 11, fabrics and non-woven fabrics woven with fibers in consideration of the texture, feel and breathability as the headrest 20 are used, and materials conventionally used in general such as natural leather and synthetic leather are used. Used.

The flexible polyurethane foam 12 is bonded to the back side of the front fabric 11 so that the texture and stretchability of the front fabric 11 are not damaged by the foamed resin that is injected and foamed inside. As the flexible polyurethane foam 12, those generally used for skin integral foam molding can be used. Preferably, the density is 18 to 60 kg / m 3 (more preferably 35 to 55 kg / m ³ ), and the hardness is 90 to 500 N ( More preferably, it is 350-450N). The thickness varies depending on the type and material of the molded product, but is about 1 mm to 15 mm, for example.

In order to prevent the liquid foamed resin from penetrating into the flexible polyurethane foam 12 and the front fabric 11 on the back side of the flexible polyurethane foam 12, the flexible polyurethane foam 12 has an anti-bleeding property and is generated with the foaming of the foamed resin. In order to prevent gas bubbles from remaining, it is necessary to have air permeability and heat resistance that does not cause thermal deformation due to contact with the foamed resin. Here, the nonwoven fabric 13 is used. In order to ensure the prevention of bleeding and air permeability.
As the nonwoven fabric 13 having such a bleeding prevention property and air permeability, as a physical property representing the bleeding prevention property, a water pressure is used, and a water pressure resistance (JIS-L1092) is 450 mmH ₂ O (mmAq) or more, Further, air permeability is used as a physical property representing air permeability, air permeability (JIS-L1096) is 0.1 to 20 cc / cm ² / s, and pore size is used as a physical property for determining the water pressure resistance and air permeability. The average pore size (measured based on the valve point method of ASTM F-361-80) needs to be 0.1 to 20 μm. The water pressure resistance of the nonwoven fabric is preferably 500 mmH ₂ O or more, more preferably 550 mmH ₂ O or more. Moreover, the air permeability of the nonwoven fabric is preferably 5 to 15 cm ² / s. The pore size of the nonwoven fabric is preferably 5 to 15 μm.

If the water pressure resistance of the nonwoven fabric 13 is less than 450 mmH ₂ O (mmAq), the liquid foamed resin will permeate and ooze out into the flexible urethane foam 12 inside.
Further, if the air permeability of the nonwoven fabric 13 is less than 0.1 cc / cm ² / s, there is a possibility that a gas (gas) generated from the foamed resin will not escape and a burrow may be generated, and the air permeability is 20 cc / cm ^2. If it exceeds / s, gas (gas) such as air may escape too much and the molded body may not expand.
Furthermore, although the air permeability and the water pressure resistance are determined to some extent depending on the pore size of the nonwoven fabric 13, if the average pore size exceeds 20 μm, the air permeability and the water pressure resistance cannot be maintained in the above ranges. The pore size may be any of these values when used as the skin material 10, and when the nonwoven fabric is processed in a subsequent process such as embossing or calendar, the pore size can be adjusted by these processing, After the adjustment, it is only necessary to ensure the above value in a state before filling with the liquid foamed resin.

  By using the nonwoven fabric 13 having such a water pressure resistance, air permeability, and pore size, the skin material 10 is constituted by the outer fabric 11, the flexible polyurethane foam 12, and the nonwoven fabric 13, and a liquid foamed resin is injected into the three-dimensionally formed internal space. By molding the skin-integrated foamed molded body integrated with the foamed resin, the liquid foamed resin penetrates into the flexible polyurethane foam 12 and oozes out, and the gas (gas) from the foamed resin does not become hard. Nest holes are not generated without wrinkles, and no wrinkles are generated on the surface dough 11, so that a desired product can be obtained and the skin material 10 does not swell due to the injection of the foamed resin and cannot be molded.

Moreover, it is preferable that the average fiber diameter of the nonwoven fabric 13 is 0.1-10 micrometers, More preferably, it is 2-5 micrometers. The fiber diameter is one of the factors that determine the pore size of the nonwoven fabric 13, and when the average fiber diameter is increased beyond 10 μm, the pore size increases and cannot be in the above pore size range. Further, the productivity of the nonwoven fabric having an average fiber diameter of less than 0.1 μm is extremely lowered.
Even if the fiber diameter of the nonwoven fabric 13 is large, the pore size can be set within the above range by post-processing such as embossing and calendering.

Furthermore, it is preferable that the fabric weight of the nonwoven fabric 13 is 30-70 g / m < ² >.
If the basis weight of the nonwoven fabric 13 is less than 30 g / m ² , the physical properties required for the nonwoven fabric cannot be obtained, and if it exceeds 70 g / m ² , the fabric becomes hard and defective molding occurs.
The basis weight of the nonwoven fabric 13 varies depending on the product as the skin-integrated foamed molded article, but for example, in the case of a headrest, a range of 30 to 50 g / m ² is preferable, and in the case of an armrest, 40 to 70 g. A range of / m ² is preferred.
In addition, even if the fabric weight of the nonwoven fabric 13 is the same, the physical properties differ depending on the fiber diameter and the like, but even in that case, it is necessary to satisfy the pore size.

  In addition, the manufacturing method of a nonwoven fabric is although it does not specifically limit, The melt blow manufacturing method is preferable. For example, when a general spunbond method, a spunlace method, or the like is used as a method for producing a nonwoven fabric, it is difficult to collect a thin fiber diameter in terms of the production method. For this reason, when trying to obtain an appropriate water pressure resistance, air permeability, and pore size, the weight per unit area tends to be high, and the rigidity tends to be high. On the other hand, according to the melt blow manufacturing method, when spinning a molten resin, it is sprayed and opened with high-speed and high-temperature air and accumulated on a belt or a wire mesh to form a non-woven fabric. Is easy. For this reason, it is possible to obtain an appropriate water pressure resistance, air permeability, and pore size in a low weight and flexible state.

  The synthetic resin constituting such a nonwoven fabric 13 is not particularly limited. However, since the nonwoven fabric is flexible, folds (corners) are less likely to appear on the surface of the skin material, which is preferable in appearance. For example, a thermoplastic elastomer is used. Of these, styrene-based thermoplastic elastomers are more preferable. For example, SEPS (styrene ethylene propylene styrene block copolymer), SIS (styrene isoprene styrene block copolymer), SBPS (styrene butylene propylene styrene block copolymer), SEBS. (Styrene ethylene butylene styrene block copolymer) and the like, and a synthetic resin having both water resistance and air permeability and having a pore size in the above range can be used.

  Moreover, it is preferable that the back surface of the skin material has a low frictional resistance. When the non-woven fabric constituting the back surface of the skin material is made of a resin having a low frictional resistance, the slipperiness at the time of sewing the sewing machine can be improved, and the working efficiency can be improved. The type of resin having low frictional resistance at this time is not particularly limited, and examples thereof include polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyolefin resins such as polypropylene, and polyamide resins. Among them, polybutylene terephthalate / polypropylene is easily made into a non-woven fabric by a melt blow production method, and polypropylene is more adhesive to other layers. Resins that are easily melted by heat are advantageous in terms of the melt blow process, thermal adhesion to other layers, etc., but from the viewpoint of suppressing and controlling the decrease in air permeability and curing due to melting, resins that are difficult to heat melt, such as modified polyethylene terephthalate Polybutylene terephthalate, polypropylene, polyamide resin and the like are advantageous. When the whole nonwoven fabric becomes hard, it causes a crease (corner) on the surface. It is most preferable to select polybutylene terephthalate from the balance of melt blowability, adhesion, and meltability control. Further, it is preferable that the nonwoven fabric adheres well to the polyurethane foam at least at a portion in contact with the polyurethane foam. Examples thereof include polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyolefin resins such as polypropylene, and polyamide resins. An adhesive or the like can be used to improve the adhesion between the polyurethane foam and the nonwoven fabric, but thermal bonding of the nonwoven fabric is preferable from the viewpoint of maintaining air permeability.

Moreover, as the nonwoven fabric 13, what uses the said resin by a single layer may be laminated | stacked, and you may make it laminate | stack another synthetic resin and comprise a nonwoven fabric. In this case, the first nonwoven fabric layer in contact with the polyurethane foam is preferably made of a resin having a high affinity with the polyurethane foam, and similarly has a high affinity with the second nonwoven fabric layer laminated with the first nonwoven fabric layer. It is preferable to consist of resin. In the case of heat bonding, for example, the basis weight is preferably set to 30 to 70 g / m ² so as not to inhibit air permeability due to melting. In order to adjust the adhesion and air permeability, a method of adjusting the porosity can be taken. In order to obtain the flexibility of the nonwoven fabric, it is preferable to provide a flexible layer made of a highly flexible nonwoven fabric. For example, a nonwoven fabric made of a thermoplastic elastomer is used. It is desirable that 50% or more of the basis weight be the flexible layer. Although the flexible layer may be the first nonwoven fabric layer, it is preferable from the viewpoint of air permeability control at the time of thermal bonding by providing the flexible layer on the first nonwoven fabric layer having high affinity with polyurethane foam. Further, another non-woven fabric may be laminated between the first non-woven fabric layer and the flexible layer in order to enhance the adhesion. The flexible nonwoven fabric that forms the flexible layer may have a high feeling of sticking, but it is even more slippery and the sewing work is performed by laminating the nonwoven fabric with high affinity with the flexible layer and using it as the back surface of the skin material. Can be improved. The nonwoven fabric used as the layer forming the back surface of the skin material preferably has a basis weight of 30 to 70 g / m ² , for example, and a resin that is advantageous for constituting the back surface is used as the material. In order to enhance the adhesion between the back layer and the flexible layer, another non-woven fabric may be further laminated. From the above, when forming a nonwoven fabric with multiple layers, for example, a first layer having a high affinity with polyurethane foam, a second layer consisting of a flexible layer, and a third layer consisting of a layer with good slipperiness constituting the back surface A stacked structure in this order is preferable.

Thus, when the nonwoven fabric and multilayer structure are a in overall water pressure resistance 450mmH ₂ O or permeability 0.1~20cc / ^cm 2 / s, the average pore size in the range of 0.1~20μm Any layer structure may be used as long as it is present. As a laminating method, a method using an adhesive and a hot embossing method can be raised, and the hot embossing method is more preferable. By laminating by the hot embossing method, the frictional resistance value of the nonwoven fabric can be lowered and the slipperiness can be improved. As a result, the workability of the sewing machine can be improved. At this time, the pressure-bonding area of the heat embossing is preferably 2 to 50%, and if it exceeds 50%, the texture becomes hard and the skin is broken and wrinkles (corners) are caused. If it is 2% or less, there is no effect of lowering the frictional resistance value.

In the examples, as specific nonwoven fabric 13, for example, as shown in an enlarged manner in FIG. 1, polybutylene terephthalate (PBT) is formed on the front and back surfaces (both surfaces) of styrene ethylene propylene styrene block copolymer (SEPS). The provided non-woven fabric of three layers 13a, 13b, and 13b is used, and the thickness (JIS-L1096) is about 0.2 to 0.4 mm, preferably about 0.3 mm, and the air permeability (JIS- L1096) used was about 18 cc / cm ² / sec, with a water pressure resistance of about 500 mmH ₂ O, and an average pore size of 15.8 μm.

  As a method of forming the skin material 10 by laminating the surface fabric 11, the flexible polyurethane foam 12 and the nonwoven fabric 13, a method using an adhesive, a method using a hot melt film, a method using a high frequency welder, a method using a frame laminate, etc. However, since the texture of the surface fabric 11 and the flexible polyurethane foam 12 is not impaired, a drying step is unnecessary, the bonding speed is fast, and the productivity is excellent, the method by frame lamination is preferable.

  The skin material 10 obtained by adhering the nonwoven fabric 13 having heat resistance and air permeability and preventing bleeding to the back surface is formed as a molded body, for example, on the outer shape of a headrest 20 for a vehicle as shown in FIG. Three-dimensional sewing is performed in a corresponding shape, and an insert part 21 such as a reinforcing material or a support is mounted inside and attached to the foaming die 31 of the molding apparatus 30, and the inserted insert part 21 and the back surface of the skin material 10 are mounted. Liquid foam resin is injected from the injection nozzle 32 into the inner space of the non-woven fabric 13 to form a headrest 20 that is a product of a skin-integrated foam-molded product in which the skin material 10 and the foamed foam resin are integrated (FIG. 2). reference). In addition, the skin material 10 for skin integral foam molding of this invention may be used in a part of the skin of the skin integral foam molded article. For example, it is also possible to use the skin material 10 for skin-integrated foam molding of the present invention only in a portion directly exposed to a liquid foamed resin.

  Thus, in the headrest 20 which is a molded body molded by the skin-integrated foam molding method, the liquid or cream-like foamed resin injected by the nonwoven fabric 13 is prevented from penetrating into the flexible polyurethane foam 12 and the outer fabric 11 and oozing out. Even when foamed resin such as injected liquid collides with the nonwoven fabric 13 without being hardened, the air permeability of the nonwoven fabric 13 does not change due to pressure, heat, or the like. It can be discharged through, and the formation of burrows can be prevented.

  Further, in the skin material 10, there is no need for a process step for forming a vent hole as in the case of providing a micro vent hole in a conventional synthetic resin film, the molding is easy, and the process can be shortened.

  Further, it is easier to sew with a sewing machine than a urethane film or the like, and it is easy to send out the nonwoven fabric 13 when it is laminated with the outer fabric 11 and the flexible polyurethane foam 12 to make the outer skin material 10, and it has excellent heat resistance. Therefore, for example, even when laminating by a frame laminating method, the skin material 10 can be easily molded without deformation.

  Examples of the present invention will be described below together with comparative examples. However, the present invention is not limited to these examples.

<Formation of evaluation sample>
In each example and comparative example, an evaluation sample was prepared as follows. A flexible polyurethane foam having a thickness of 5 mm and a hardness of 35 N (JIS K6400-2) and a nonwoven fabric were laminated by a frame laminating method. Two pieces of this were cut out into a rectangle of 300 mm in length and 200 mm in width, and a bag-like evaluation sample was prepared by sewing the three sides with an industrial sewing machine using polyester yarn so that the nonwoven fabric was inside. That is, the evaluation sample has a structure such as a skin material without a surface fabric. In addition, what is a nonwoven fabric is a structure which laminated | stacked in order of the 1st layer and the 2nd layer, and what is 3 layers is a structure laminated | stacked in order of the 1st layer, the 2nd layer, and the 3rd layer, Each of the first layers was laminated so as to be in contact with the flexible polyurethane foam. In addition, all those subjected to the heat embossing treatment were round dot shapes, and the crimping area of the thermocompression bonding portion was 3% of the entire surface area (600 cm ² ).
In this evaluation sample, a foamed resin (100 parts by weight of polyether polyol, 70 parts by weight of a mixture of TDI-80 and polymeric MDI as polyisocyanate, dimethylethanolamine (2-dimethylaminoethanol, DMEA) as a reactive catalyst) 2.5 parts by weight, 1.0 part by weight of triethylenediamine (TEDA) as a non-reactive catalyst, 3.5 parts by weight of water as a foaming agent and 1 part by weight of silicone oil as a foam stabilizer) are injected from an injection nozzle. The foamed molded body integrated with the evaluation sample was obtained by foaming and curing.

<Evaluation method>
In this example, the prevention of seepage of the foamed resin by the nonwoven fabric and the generation of burrows due to the generation of gas from the foamed resin, the sewing performance, and the peel resistance were evaluated. The evaluation method is as follows.
<Prevention of bleeding>
The polyurethane stock solution is injected from the top opening of the skin material, and after curing, the exuding state of the injected urethane foam in the range of 2 cm to 5 cm in height from the bottom sewn part is visually evaluated, and the flexible polyurethane foam of this part is After peeling off, the hardness of six locations was measured with a rubber hardness meter to determine the average hardness, and the bleeding prevention property was evaluated from the change from the hardness of the original flexible polyurethane foam. The evaluation criteria are as follows.
○: The injected urethane foam does not penetrate to the surface of the skin material, and the change in surface hardness is less than 10N. ×: The injected urethane foam penetrates to the surface of the skin material, and the change in surface hardness is 10N or more Occurrence>
The cross section of the evaluation sample was observed, and the presence or absence of burrows (voids) at the interface between the skin material and the injected urethane foam was judged visually.
◯: No burrow (void) is generated ×: Nest hole (void) is observed <sewing machine feedability>
The sewing machine feedability when sewing the evaluation sample was evaluated.
○: The nonwoven fabric can be smoothly fed and the seam is straight △: The nonwoven fabric is slightly caught but the seam is straight ×: The nonwoven fabric cannot be smoothly fed and the seam is not aligned <Release Resistance>
The peel strength of the polyurethane foam and nonwoven fabric of the skin material was evaluated.
○: Even if the nonwoven fabric is pulled strongly, the interface is adhered to the polyurethane foam.
Δ: Even if the nonwoven fabric is pulled lightly, it adheres to the polyurethane foam.
Pulling strongly will peel the interface.
X: When the nonwoven fabric is pulled lightly, it peels off from the polyurethane foam.
When the nonwoven fabric was pulled, the polyurethane foam or the nonwoven fabric was destroyed before the interface.

Example 1
Evaluation sample: Polybutylene terephthalate (PBT, average fiber diameter) having a basis weight of 20 g / m ^{2 on} one side of a styrene elastomer resin meltblown nonwoven fabric (second layer) (SEPS, average fiber diameter 4.5 μm) having a basis weight of 25 g / m ² A two-layer laminated nonwoven fabric obtained by thermocompression bonding of a melt blown nonwoven fabric (first layer) made of 3.5 μm with hot embossing was used.
As shown in Table 1, the measured values of this nonwoven fabric are as follows: air permeability (JIS-L1096) is 12.5 cc / cm ² / s, water pressure resistance (JIS-L1092) is 529 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 12.1 μm.
A foamed resin was injected into the evaluation sample obtained from the nonwoven fabric through an injection nozzle, foamed, and cured to obtain a foamed molded body integrated with the evaluation sample.
The average surface hardness (JIS K6400-2) of the obtained foamed molded article was 37N, the change in surface hardness was less than 10N, there was no penetration of the foamed resin into the surface, and the feel of the flexible polyurethane foam remained as it was, There was no burrow caused by bubbles. Further, the machine feedability was slightly caught, but the seam was a straight line. Furthermore, the peel resistance was high (see Table 1).

(Example 2)
Evaluation sample: From a polybutylene terephthalate (PBT, average fiber diameter of 3.5 μm) having a basis weight of 30 g / m ^{2 on} one side of a styrene elastomer resin meltblown nonwoven fabric (SEPS, average fiber diameter of 4.5 μm) having a basis weight of 35 g / m ² A two-layer laminate nonwoven fabric obtained by thermocompression bonding of the resulting meltblown nonwoven fabric with hot embossing was used.
As shown in Table 1, each measured value of this nonwoven fabric has an air permeability (JIS-L1096) of 6.6 cc / cm ² / s, a water pressure resistance (JIS-L1092) of 620 mmH ₂ O, and a pore size (ASTMF). The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 8.6 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded product was 36N, the change in surface hardness was less than 10N, there was no penetration of the foamed resin into the surface, and the feel of the flexible polyurethane foam remained as it was, There was no burrow caused by bubbles. Further, the machine feedability was slightly caught, but the seam was a straight line. Furthermore, the peel resistance was high (see Table 1).

(Example 3)
Evaluation sample: A single layer of polypropylenelene resin meltblown nonwoven fabric (PP, average fiber diameter: 3.0 μm) having a basis weight of 70 g / m ² was used.
As shown in Table 1, the measured values of this nonwoven fabric are as follows: air permeability (JIS-L1096) is 11.7 cc / cm ² / s, water pressure resistance (JIS-L1092) is 918 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring device based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 10.4 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded product was 43N, the change in surface hardness was less than 10N, and there was almost no penetration of the foamed resin into the surface, and the feel of the flexible polyurethane foam remained as it was. There was also no generation of burrows due to bubbles. Also, the machine feedability was good, it could be fed smoothly, and the seam was straight. Furthermore, the peel resistance was high (see Table 1).

Example 4
Evaluation sample: Styrene elastomer resin melt blown nonwoven fabric (SEPS, average weight of 25 g / m ²⁾ of the same resin on one side of a styrene elastomer resin melt blown nonwoven fabric (SEPS, average fiber diameter 4.5 μm) having a basis weight of 15 g / m ² A two-layer laminate nonwoven fabric obtained by thermocompression bonding with a fiber diameter of 4.5 μm) by hot embossing was used.
As shown in Table 1, the measured values of this nonwoven fabric were as follows: air permeability (JIS-L1096) was 18.4 cc / cm ² / s, water pressure resistance (JIS-L1092) was 560 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring apparatus based on a valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 14.8 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded article was 44N, the change in surface hardness was less than 10N, the penetration of the foamed resin into the surface was scarce, and the feel of the flexible polyurethane foam remained, There was no burrow caused by bubbles. Further, the machine feedability was slightly caught, but the seam was a straight line. The peel resistance was moderate (see Table 1).

(Example 5)
Evaluation sample: A single-layer product of a styrene-based elastomer resin meltblown nonwoven fabric (SEPS, average fiber diameter: 4.5 μm) having a basis weight of 65 g / m ² was used.
As shown in Table 1, the measured values of this nonwoven fabric are as follows: air permeability (JIS-L1096) is 15.4 cc / cm ² / s, water pressure resistance (JIS-L1092) is 600 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 13.3 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded article was 39N, the change in surface hardness was less than 10N, the penetration of the foamed resin into the surface was almost none, and the feel of the flexible polyurethane foam remained as it was. There was also no generation of burrows due to bubbles. Further, the machine feedability was slightly caught, but the seam was a straight line. The peel resistance was moderate (see Table 1).

(Example 6)
Evaluation sample: Styrene elastomer resin (SEPS, average fiber diameter of 4.5 μm) having a basis weight of 25 g / m ^{2 on} one side of a melt blown nonwoven fabric (PBT, average fiber diameter of 3.5 μm) made of polybutylene terephthalate having a basis weight of 20 g / m ² A two-layer nonwoven fabric obtained by thermocompression bonding of a melt blown nonwoven fabric made of
As shown in Table 1, the measured values of this nonwoven fabric are as follows: air permeability (JIS-L1096) is 12.5 cc / cm ² / s, water pressure resistance (JIS-L1092) is 529 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 12.1 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded product was 35N, the change in surface hardness was less than 10N, there was no penetration of the foamed resin into the surface, and the feel of the flexible polyurethane foam remained as it was, There was no burrow caused by bubbles. Also, the machine feedability was good, it could be fed smoothly, and the seam was straight. The peel resistance was moderate (see Table 1).

(Example 7)
Evaluation sample: a basis weight of 20 g / ^{m 2} of a styrene elastomer resin melt blown nonwoven fabric (SEPS, average fiber diameter 4.5 [mu] m) from both sides in the basis weight of 10 g / ^{m 2} of polybutylene terephthalate (PBT, average fiber diameter 3.5 [mu] m) A three-layer laminated nonwoven fabric obtained by thermocompression bonding of the resulting meltblown nonwoven fabric with hot embossing was used.
As shown in Table 1, the measured values of this nonwoven fabric were an air permeability (JIS-L1096) of 16.2 cc / cm ² / s, a water pressure resistance (JIS-L1092) of 495 mmH ₂ O, and a pore size (ASTMF). The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 12.6 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded product was 36N, the change in surface hardness was less than 10N, there was no penetration of the foamed resin into the surface, and the feel of the flexible polyurethane foam remained as it was, There was no burrow caused by bubbles. Also, the machine feedability was good, it could be fed smoothly, and the seam was straight. Furthermore, the peel resistance was high (see Table 1).

(Comparative Example 1)
Evaluation sample: basis weight of 10 g / ^{m 2} styrene elastomer resin melt blown nonwoven fabric (SEPS, average fiber diameter 4.5 [mu] m) on one side of the basis weight is 10 g / ^{m 2} of polybutylene terephthalate (PBT, average fiber diameter 3.5 [mu] m) A two-layer nonwoven fabric obtained by thermocompression bonding of a meltblown nonwoven fabric made of the above with hot embossing was used.
As shown in Table 1, the measured values of this nonwoven fabric were 50.0 cc / cm ² / s in air permeability (JIS-L1096), 370 mmH ₂ O in water pressure resistance (JIS-L1092), and pore size (ASTMF). The average value of a porous material automatic pore measuring device based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 19.6 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded body is 46N, the change in surface hardness is 10N or more, the foamed resin penetrates the surface, the feel of the flexible polyurethane foam is lost, and it becomes hard It was. Moreover, the air permeability was high and the evaluation sample was difficult to swell. The machine feedability was good, the machine could be fed smoothly, and the seam was straight. The peel resistance was high (see Table 1).

(Comparative Example 2)
Evaluation sample: Polybutylene terephthalate (PBT, average fiber diameter of 3.5 μm) having a basis weight of 10 g / m ^{2 on} one surface of a styrene elastomer resin melt blown nonwoven fabric (SEPS, average fiber diameter of 4.5 μm) having a basis weight of 15 g / m ² A two-layer nonwoven fabric obtained by thermocompression bonding of a meltblown nonwoven fabric made of the above with hot embossing was used.
As shown in Table 1, each measured value of this nonwoven fabric has an air permeability (JIS-L1096) of 33.0 cc / cm ² / s, a water pressure resistance (JIS-L1092) of 426 mmH ₂ O, and a pore size (ASTMF). The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 17.1 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded body is 46N, the change in surface hardness is 10N or more, the foamed resin penetrates the surface, and the feel of the flexible polyurethane foam is considerably lost. It was. In addition, there was no generation of burrows due to bubbles, the machine feedability was good, the machine was fed smoothly, and the seam was straight. The peel resistance was high (see Table 1).

(Comparative Example 3)
Evaluation sample: a basis weight of 10 g / ^{m 2} of polybutylene terephthalate on one side of (PBT, average fiber diameter 3.5 [mu] m) meltblown nonwoven fabric made of 100 percent, basis weight same resin polybutylene terephthalate at 30g / ^{m 2} (PBT, average fiber A two-layer nonwoven fabric obtained by thermocompression bonding of a meltblown nonwoven fabric having a diameter of 3.5 μm) by hot embossing was used.
As shown in Table 1, the measured values of this nonwoven fabric are as follows: air permeability (JIS-L1096) is 15.3 cc / cm ² / s, water pressure resistance (JIS-L1092) is 325 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring device based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 13.5 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded product was 48N, the change in surface hardness was 10N or more, the foamed resin penetrated the surface, and the soft polyurethane foam lost its feel and became hard. It was. In addition, there was no generation of burrows due to bubbles, the machine feedability was good, the machine was fed smoothly, and the seam was straight. The peel resistance was high (see Table 1).

(Comparative Example 4)
Evaluation sample: A single-layer product of a melt blown nonwoven fabric made of polybutylene terephthalate (PBT, average fiber diameter 3.5 μm) having a basis weight of 40 g / m ² was used.
As shown in Table 1, the measured values of this nonwoven fabric are as follows: air permeability (JIS-L1096) is 20.8 cc / cm ² / s, water pressure resistance (JIS-L1092) is 254 mmH ₂ O, and pore size (ASTMF) The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 14.5 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded body is 47N, the change in surface hardness is 10N or more, the foamed resin penetrates the surface, and the feel of the flexible polyurethane foam is considerably lost. It was. In addition, there was no generation of burrows due to bubbles, the machine feedability was good, the machine was fed smoothly, and the seam was straight. The peel resistance was high (see Table 1).

(Comparative Example 5)
Evaluation sample: A single-layer product of a polypropylene-lens resin meltblown nonwoven fabric (PP, average fiber diameter: 3.0 μm) having a basis weight of 40 g / m ² was used.
As shown in Table 1, each measured value of this nonwoven fabric is 32.6 cc / cm ² / s in air permeability (JIS-L1096), 568 mmH ₂ O in water pressure resistance (JIS-L1092), and has a pore size (ASTMF). The average value of a porous material automatic pore measuring device based on a valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 19.0 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing. At this time, the air permeability was high and the evaluation sample was difficult to swell.
The average surface hardness (JIS K6400-2) of the obtained foamed molded product was 46N, and the change in surface hardness was 10N or more. The machine feedability was good, it could be fed smoothly and the seam was straight. Nest holes were not generated by bubbles. The peel resistance was high (see Table 1).

(Comparative Example 6)
Evaluation sample: A single-layer product of a styrene-based elastomer resin meltblown nonwoven fabric (SEPS, average fiber diameter: 3.0 μm) having a basis weight of 45 g / m ² was used.
As shown in Table 1, each measured value of this nonwoven fabric is 45.3 cc / cm ² / s in air permeability (JIS-L1096), 395 mmH ₂ O in water pressure resistance (JIS-L1092), and has a pore size (ASTMF). The average value of a porous material automatic pore measuring apparatus based on the valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 22.8 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained foamed molded body is 47N, the change in surface hardness is 10N or more, the foamed resin penetrates the surface, the feel of the flexible polyurethane foam is lost, and it becomes hard It was. Moreover, the air permeability was high and the evaluation sample was difficult to swell. The machine feedability was slightly caught, but the seam was a straight line. The peel resistance was moderate (see Table 1).

(Comparative Example 7)
Evaluation sample: A single layer product of polyurethane resin melt blown nonwoven fabric (PU, average fiber diameter 5.0 μm) having a basis weight of 50 g / m ² was used.
As shown in Table 1, the measured values of this nonwoven fabric were 51.5 cc / cm ² / s in air permeability (JIS-L1096), 383 mmH ₂ O in water pressure resistance (JIS-L1092), and pore size (ASTMF) The average value of a porous material automatic pore measuring apparatus based on a valve point method of -361-80 (manufactured by Palm Porometer POROUS MATERIALS, INC.) Was 26.4 μm.
A foamed resin integrated with the evaluation sample was obtained by injecting a foamed resin into the evaluation sample obtained from the nonwoven fabric through an injection nozzle to cause foaming and curing.
The average surface hardness (JIS K6400-2) of the obtained molded foam is 50N, the change in surface hardness is 10N or more, the foamed resin penetrates the surface, and the soft polyurethane foam loses its feel and becomes hard. It was. Further, a burrow was generated, the air permeability was high, and the evaluation sample was difficult to swell, the sewing machine feedability was poor, and the moldability was poor. Moreover, the peel resistance was low (see Table 1).

(Comparative Example 8)
Evaluation sample: A polyurethane resin film (PU) having a basis weight of 50 g / m ² was used instead of the nonwoven fabric.
The average surface hardness (JIS K6400-2) of the obtained molded foam was 36N, the change in surface hardness was less than 10N, and there was no penetration of the foamed resin into the surface, but burrows were generated. Also, the machine feedability was poor and the moldability was poor. Moreover, the peel resistance was low (see Table 1).

(Comparative Example 9)
Evaluation sample: A single layer product of polyethylene terephthalate resin spunlace nonwoven fabric (PET, average fiber diameter 15.0 μm) having a basis weight of 80 g / m ² was used.
As shown in Table 1, each measured value of this nonwoven fabric had an air permeability (JIS-L1096) of 240.0 cc / cm ² / s. In addition, the water pressure resistance (JIS-L1092) and the average pore size (based on ASTMF-361-80 valve point method, porous material automatic pore measuring device Palm Porometer manufactured by POROUS MATERIALS, INC.) Could not be measured. .
The average surface hardness (JIS K6400-2) of the obtained foamed molded product is 70N, the change in surface hardness is 10N or more, the foamed resin penetrates the surface, and the feel of the flexible polyurethane foam is lost. It became hard. Moreover, the air permeability was high and the evaluation sample was difficult to swell. In addition, there was no generation | occurrence | production of the nest hole by the bubble, the sewing machine feedability was good, it was able to feed smoothly, and the seam was a straight line. The peel resistance was high (see Table 1).

It is sectional drawing concerning one Embodiment of the skin material for skin integral foam molding of this invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic perspective view of a vehicle headrest as an example of a molded body according to an embodiment of a skin material for integral foam molding of the present invention. It is a schematic sectional drawing of the formation process of the headrest for vehicles of an example of the molded object concerning one Embodiment of the skin material for skin integrated foam molding of this invention.

Explanation of symbols

10 Skin material 11 Surface fabric 12 Flexible polyurethane foam 13 Non-woven fabric 20 Headrest (molded body)
21 Insert component 30 Molding device 31 Foaming mold 32 Injection nozzle

Claims (6)

A skin material for integral skin foam molding that is sewn into the outer shape of a molded body and injects a liquid foam resin into the inside to foam and integrate.
It consists of a surface fabric disposed outside the molded body, a polyurethane foam adhered to the inside of the surface fabric, and a nonwoven fabric that adheres to the inside of the polyurethane foam and has anti-bleeding properties and breathability.
The non-permeability of the nonwoven fabric is a water pressure resistance of 450 mmH ₂ O or more, the air permeability is an air permeability of 0.1 to 20 cc / cm ² / s, and an average pore size is 0.1 to 20 μm. A skin material for integral foam molding of the skin.   The skin material for skin-integrated foam molding according to claim 1, wherein the nonwoven fabric has an average fiber diameter of 0.1 to 10 µm. The basis weight of the nonwoven fabric, according to claim 1 or 2 skin material for an integral skin foam molded according characterized in that it is a 30~70g / m ^2.   The skin material for skin-integrated foam molding according to any one of claims 1 to 3, wherein the nonwoven fabric is a nonwoven fabric obtained by a melt blow manufacturing method.   The said nonwoven fabric is comprised by the multilayer which laminated | stacked the nonwoven fabric which consists of a single layer of the nonwoven fabric which consists of a thermoplastic elastomer resin, or another resin on this, The skin integrated body in any one of Claims 1-4 characterized by the above-mentioned. Skin material for foam molding.   The nonwoven fabric is composed of a two-layer or three-layer laminate formed by thermally bonding a nonwoven fabric made of polybutylene terephthalate resin to at least one surface or both surfaces of a nonwoven fabric made of a thermoplastic elastomer resin. The skin material for skin integral foam molding in any one of Claims 1-5.

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