JP2012006212A - Surface material for integrally foaming with surface and integrally foamed-molded article with surface - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a surface material for integrally foaming with the surface showing little limitation to a choice of the material of the surface by enabling thinning.SOLUTION: The surface material S for integrally foaming with the surface is a laminate obtained by integrally laminating a sheet-like polyurethane foam 6 of a liquid resin-non-permeable polyurethane foam on the surface 7, and is 1 to 5 mm thick. The polyurethane foam 6 is obtained by using at least a polyol component, an isocyanate compound and a catalyst, is a thin sheet-like material whose final thickness is 0.5 to 3 mm as the foamed body, and has self-made thin skin layers 6a on both the surfaces.

Description

  The present invention relates to a skin integrated foam material and a skin integrated foam-molded product that can be applied to a vehicle headrest, armrest, seat cushion, and the like.

Most of the conventional skin-integrated foaming material 100 has a skin 101, a continuous foamed soft polyurethane foam 102 as a wadding material, and a urethane foam stock solution that becomes urethane foam 103 after curing penetrates into the wadding material 102. It is configured by a three-layer structure including a non-breathable resin film 104 disposed as a barrier layer for prevention. By simply bonding the non-breathable resin film 104 to the skin 101 without using the open-celled flexible polyurethane foam 102 as the wadding material, wrinkles can easily occur when foaming integrally, and the open-celled flexible polyurethane foam 102 is necessary to give a soft feel to the surface of the molded product obtained by integral foaming.
However, since the open-cell flexible polyurethane foam 102 generally has high air permeability and has a large hole in the cell membrane, if the resin film 104 of the barrier layer is not present when foamed integrally, the urethane foam undiluted solution becomes a wadding material. After reaching the inside of 102 and the skin 101, it is cured, so that partial hardness unevenness is produced and the feeling becomes poor.
For these reasons, the skin material 100 has conventionally been configured with a structure of three layers or more, but as the number of layers increases, the manufacturing cost becomes higher due to the complexity of the manufacturing process, Since the non-breathable resin film 104 is used as a raw material permeation preventive layer (barrier layer), there is a problem that it is easy to get stuffy, especially in summer or when sitting for a long time.
For this reason, there has been proposed a technique for manufacturing an integrally foamed product using a skin material having a two-layer structure of a skin and a wadding material without using the resin film 104 of the barrier layer. For example, in Japanese Patent Application Laid-Open No. 2004-268406, there is no resin film by using an open cell flexible polyurethane foam having a permeability of 5 cc / cm 2 / sec or less and having a plurality of fine holes as a wadding material, It is disclosed that the urethane stock solution is difficult to penetrate to the skin layer.

JP 2004-268406 A JP-A-5-329978

However, the urethane foam is thinly sliced with a predetermined thickness from a large urethane foam block, and the cell structure of substantially continuous foam is exposed without having a skin layer on the surface. Therefore, even if the urethane foam stock solution does not penetrate into the wadding layer, a slight amount (1 to 3 mm) of impregnation always occurs. Depending on the degree of impregnation, a hard impregnation layer may be formed. May damage the soft texture. Moreover, it is necessary to make the urethane foam wading material about 1-2 mm thicker than the wadding material 102 used in the conventional three-layer structure, for example, 4-5 mm thick so as not to feel impregnation as much as possible. For this reason, the final thickness of the integral foaming skin material is increased, making it difficult to secure a seam allowance in the process of cutting and sewing into a predetermined shape, which is not suitable for complex shapes.
JP-A-5-329978 discloses an integral foaming skin material in which a latex foam layer is formed on a breathable skin. This latex foam layer is a large foam block as described above. Since the latex foam raw material is directly coated on the epidermis and then removed by heating and cured, the skin layer is substantially formed on the surface. As a result, the penetration of the urethane foam stock solution into the wadding material is extremely reduced, and a soft texture can be maintained. However, the latex foam stock solution, which is such an emulsion, inhibits the curing reaction when the evaporation of moisture is hindered. In some cases, foam cells may become coarse, and adhesion to the epidermis may be hindered. Therefore, for example, it is not suitable for a non-breathable skin such as synthetic leather, and there is a limit to the skin that can be used.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a skin material for foam integrated with a skin that can be thinned and has few restrictions on material selection. Another object of the present invention is to provide a skin-integrated foam-molded article provided with such a skin-integrating foam material.

  The skin integrated foam material according to the present invention is obtained using at least a polyol component, an isocyanate compound, and a catalyst, and is formed into a thin sheet so that the final thickness as a foam body is 0.5 mm to 3 mm, and A thickness of a laminated body obtained by laminating and integrating a sheet-like polyurethane foam having a thin skin layer by self-formation on both surfaces and a skin is 1 mm to 5 mm.

  This skin-integrated skin material has a two-layer structure consisting of a skin and a wadding material (a sheet-like polyurethane foam with a self-formed thin skin layer) without using a barrier layer such as a resin film. Is easy, and the cost can be reduced. Moreover, since the foamed urethane undiluted solution injected into the bag-like skin material is not impregnated into the skin material, the increase in the hardness of the skin material can be suppressed, and the skin material can be made thin. Can do. In addition, since a thin skin material can be used, sewing with a complicated design becomes possible. Furthermore, it goes without saying that a breathable woven fabric can be used for the skin, and a woven fabric having a non-breathable backing layer or a non-breathable synthetic leather can also be employed. It can be said that the skin material has few restrictions on the material selection of the skin.

  The skin-integrated foam-molded product according to the present invention is formed by cutting and sewing the skin-integrating foam material according to any one of claims 1 to 4 into a predetermined shape to form a bag-shaped trim cover. It is arranged so as to be in contact with a mold, and a urethane foam obtained by injecting a urethane foam stock solution into the trim cover to be foamed and cured is integrated with the trim cover.

  The present invention makes it possible to reduce the thickness of the skin material for foam integrated with the skin, thereby reducing the choice of material for the skin.

It is a perspective view which shows one Embodiment of the skin integral foam molded product which concerns on this invention. It is sectional drawing which follows the AA line of FIG. It is sectional drawing which shows the skin material for skin integrated foaming which concerns on this invention. It is sectional drawing which shows the conventional skin material.

  Hereinafter, preferred embodiments of a skin integrated foam material and a skin integrated foam-molded product according to the present invention will be described in detail with reference to the drawings.

  As shown in FIGS. 1 and 2, the skin-integrated foam-molded product 1 includes a trim cover 2 formed into a bag shape by cutting and sewing the skin material S, and a urethane foam 3 filled in the trim cover 2. And a headrest stay 5 that is fixed to the headrest frame 4 in the urethane foam 3 and protrudes from the trim cover 2.

  As shown in FIG. 3, the skin material S is a laminate obtained by laminating and integrating a sheet-like polyurethane foam 6 made of a liquid resin-impermeable open-cell flexible polyurethane foam and a skin 7, and has a thickness of 1 mm. ~ 5 mm. The thickness of the polyurethane foam 6 is suitably 0.5 mm to 3 mm.

  This polyurethane foam 6 is obtained by using at least a polyol component, an isocyanate compound, and a catalyst, and is formed into a thin sheet so that the final thickness as a foam body is 0.5 mm to 3 mm. Self-formed thin skin layer 6a is provided on both sides and has a soft feel.

  This sheet-like polyurethane foam 6 is obtained by foam-curing a prepolymer having an isocyanate group as a terminal group obtained by synthesizing a polyol component and an isocyanate component with high-temperature steam.

  As the skin 7 applied to the skin material S, a breathable woven fabric, a woven fabric provided with a non-breathable backing layer, or a non-breathable synthetic leather is suitable.

  This skin integrated foam material S has a two-layer structure of a skin 7 and a wadding material (sheet-like polyurethane foam having a thin skin layer by self-formation) 6 without using a barrier layer such as a resin film. Therefore, manufacturing is easy and cost reduction can be achieved. In addition, since the foamed urethane stock solution injected into the bag-shaped trim cover 2 is not impregnated in the trim cover 2, an increase in the hardness of the trim cover 2 can be suppressed. Can be thinned. The trim cover 2 can be sewed with a complicated design by using the thin skin material S. Needless to say, a breathable woven fabric can be used for the skin 7, and a woven fabric having a non-breathable backing layer or a non-breathable synthetic leather can also be employed. It can be said that the material S has few restrictions on the material selection of the skin 7.

  A headrest (skin integrated foam molded product) 1 using such a skin integrated foam material S will be described.

  The sheet-like skin material S is cut into a plurality of cut pieces so as to form a bag-like trim cover 2. Thereafter, the trim pieces are sewn to form a bag-like trim cover 2. Further, since the headrest stay 5 is prepared in a state where the headrest 4 is welded to the headrest 4, the headrest stay 5 protrudes from the trim cover 2 when the frame 4 is accommodated in the trim cover 2 and is sewn to the trim cover 2. Let The front end of the resin injection nozzle is inserted into the trim cover 2 from the outside.

  In this state, the skin 7 is disposed so as to contact the cavity surface of the mold, and after the headrest stay 5 and the nozzle are set at predetermined positions of the mold, the mold is closed. Thereafter, the urethane foam stock solution is injected into the trim cover 2 through a nozzle, and the urethane foam stock solution is foamed in the trim cover 2.

  Then, after a predetermined time has passed in the mold closed state, the urethane foam stock solution is cured in the trim cover 2 to become the urethane foam 3. In this process, the polyurethane foam 6 and the urethane foam of the trim cover 2 are formed in the mold. The body 3 is integrated. After the urethane foam stock solution is cured, the mold is opened and the headrest 1 is taken out of the mold to complete the molding of the headrest 1.

  It goes without saying that the present invention is not limited to the embodiment described above. For example, the present invention can be applied not only to a headrest but also to an armrest, a seat cushion, and the like for in-vehicle use.

  DESCRIPTION OF SYMBOLS 1 ... Skin integral foam molding (headrest), 2 ... Trim cover, 3 ... Urethane foam, 6 ... Polyurethane foam, 6a ... Skin layer, 7 ... Skin, S ... Skin material.

Claims (4)

  A sheet obtained by using at least a polyol component, an isocyanate compound, and a catalyst, formed into a thin sheet shape so that the final thickness as a foam body is 0.5 mm to 3 mm, and having a thin skin layer by self-forming on both sides A skin material for foam integrated with a skin, characterized in that the thickness of the laminated body obtained by laminating and integrating a shaped polyurethane foam and a skin is 1 mm to 5 mm.   2. The skin-integrated foam according to claim 1, wherein the sheet-like polyurethane foam is obtained by foam-curing a prepolymer having an isocyanate group as a terminal group obtained by synthesizing a polyol component and an isocyanate component with high-temperature steam. Skin material.   The skin material for foam integrated with a skin according to claim 1 or 2, wherein the skin is a woven fabric having a non-breathable backing layer or a non-breathable synthetic leather.   Cut the skin integrated foam material according to any one of claims 1 to 3 into a predetermined shape, sew and form a bag-like trim cover, and arrange the skin to contact the mold, A skin-integrated foam-molded article obtained by integrating a urethane foam obtained by injecting a urethane foam stock solution into the trim cover and foaming and curing, and the trim cover.