JP2018140000A - Skin material and integral foam molded article using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a skin material of a two-layer structure capable of giving a soft touch to a surface of the skin material without using a wadding material and preventing infiltration of an urethane foaming stock solution into the skin material, and an integral foam molded article using the same.SOLUTION: In an integral foam molded article comprising a molded member formed of a foam material and a skin material covering the molded member, the skin material comprises a skin portion forming a surface of the skin material and a film portion which is provided on a back side of the skin portion and is supplied in a liquid form to the skin portion and directly laminated. The film portion is formed of a polymeric material and a surface of the film portion in contact with the molded member is subjected to reforming treatment by corona discharge.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a skin material used for a vehicle seat and an integral foam molded product using the same.

  As described in Patent Document 1, for example, a skin material used for a conventional vehicle seat has a three-layer structure of a skin layer, an elastic layer, and a non-woven fabric layer, and the skin material stacked on the three layers is heated with a press. A method is described in which a headrest is manufactured by pressurizing and forming a three-layer skin material to form a three-dimensional structure and then filling urethane foam inside.

  On the other hand, Patent Document 2 discloses a two-layer structure in which a surface layer and a wadding material are laminated to form a two-layered sheet trim cover, and the surface of the wadding material is heated by a burner and melted. A method for manufacturing a headrest by forming a seat trim cover and filling urethane foam inside is described.

  Furthermore, in Patent Document 3, a plurality of skin pieces bonded together with a polyurethane film as a backing material are stitched together into a bag shape on a surface formed of genuine leather, fabric, synthetic leather, etc., and the stitched portion is laminated with a resin film on the nonwoven fabric. The structure covered with a strip is described.

JP 2014-171801 A Japanese Patent No. 5734698 JP 2014-110833 A

  The skin material described in Patent Document 1 can give a soft feel to the surface of the skin material by sandwiching a wadding material in the middle. However, since it has a three-layer structure, there is a problem in that it takes time to handle each material and the process of laminating the three layers, which increases the manufacturing cost.

  On the other hand, Patent Document 2 describes a configuration in which a sheet trim and cover, which is a sheet skin material, is composed of a skin material and a wadding material, thereby reducing the number of parts and relatively simplifying the lamination process. ing. Further, it is described that a uniform low air-permeable layer is formed by heating the surface of the wadding material, pressing the molten surface and stretching the wadding cell film. However, in the configuration described in Patent Document 2, since the resin film as a barrier layer corresponding to the nonwoven fabric of Patent Document 1 is not used, the urethane foam stock solution penetrates into the low-air-permeable layer formed on the wadding material and is cured. In addition, unevenness in hardness may occur partially.

  Further, even in the configuration described in Patent Document 3, since the resin film as a barrier layer corresponding to the nonwoven fabric of Patent Document 1 is not used for the plurality of skin pieces sewn in a bag shape, the urethane foam stock solution is wadding. There is a possibility that the non-uniformity of hardness may occur due to penetration into the low-air permeability layer formed on the material and curing.

  The present invention solves the above-mentioned problems of the prior art and can prevent the urethane foam undiluted solution from penetrating into the skin material. The surface of the skin material can be softly touched without using a wadding material or polyurethane film. It is intended to provide a two-layered skin material capable of producing the same and an integral foam molded product using the same.

  In order to solve the above-mentioned problems, in the present invention, a skin material covering a member formed of a foam material is formed by directly laminating a skin portion that forms the surface of the skin material and a back side of the skin portion. It is characterized by comprising a film portion made of a polymer material subjected to a modification treatment on the surface in contact with the material.

  In order to solve the above-described problems, in the present invention, a member formed of a foam material having a two-layer structure of a skin part and a film part formed by directly laminating on the back side of the skin part is provided. In the covering skin material, the film portion is formed of a polymer material, and the surface of the film portion in contact with the foam material is subjected to a modification treatment by corona discharge.

  In order to solve the above-described problems, in the present invention, in the integral foam molded article provided with a molded member formed of a foam material and a skin material covering the molded member, the skin material is the surface of the skin material. A film part formed on the back side of the skin part and laminated directly on the skin part, the film part is formed of a polymer material, and the film part is in contact with the molded member of the film part. It is characterized by being subjected to a modification treatment by corona discharge.

  According to the present invention, it is possible to prevent the urethane foam stock solution from penetrating into the skin material, and to have a soft feel on the surface of the skin material without using a wadding material or a polyurethane film. A skin material and an integral foam molded product using the same can be provided.

It is a block diagram which shows the apparatus structure for forming the skin material based on the Example of this invention. It is sectional drawing of the skin material which concerns on the Example of this invention. It is sectional drawing of the metal mold | die and skin member which show the state which concerns on the Example of this invention and attached the skin member shape | molded for headrests to the metal mold | die, and started supplying urethane foam material inside. It is sectional drawing of the metal mold | die and skin member which concern on the Example of this invention, and shows the state by which the skin member shape | molded for headrests was mounted | worn with the metal mold | die, and the inside was filled with foaming urethane. It is an example of the integral foam molding part which concerns on the Example of this invention, and is sectional drawing of a headrest. 1 is a perspective view of a vehicle seat as an example of an integrally foamed molded part according to an embodiment of the present invention. FIG.

  In the present invention, the skin material has a two-layer structure in which the skin and the resin film layer are overlapped, so that the lamination process is simplified and the resin film layer prevents the urethane foam stock solution from penetrating into the skin. In addition, by forming the skin material having such a structure into a bag shape and filling the inside with foamed urethane, it is possible to manufacture an integrally foamed molded product such as a headrest or an armrest without causing appearance problems. I made it.

  Embodiments of the present invention will be described below with reference to the drawings.

  Below, the formation method of the skin material in a present Example and the integral foam molding method using this skin material are demonstrated.

[Method of forming skin material]
A method for forming the skin material in the present embodiment will be described with reference to FIG.
In FIG. 1, 110 is a skin and 120 is a resin film layer. 131 is a resin film material extruder for supplying the raw material (liquid) of the resin film layer 120. Reference numeral 132 denotes a cooling roller for cooling the resin film material 121 supplied on the skin 110 and forming the resin film layer 120 to have a uniform thickness. Reference numeral 133 denotes a corona discharge generator, which generates a corona discharge in the vicinity of the surface of the resin film layer 120 formed on the skin 110, thereby improving the surface of the resin film layer 120 to facilitate adsorption. 140 is a supply roller for supplying the skin 110, and 150 is a take-up roller for winding the skin 110 having the resin film layer 120 formed on the surface.

  A transport unit (not shown) that transports the resin film material extruder 131, the cooling roller 132, the corona discharge generator 133, the supply roller 140, the take-up roller 150, and the skin 110 in the direction of the arrow is controlled by the control unit 160. .

  The reason why the surface of the resin film layer 120 is easily adsorbed by modifying the surface by corona discharge is that in the later step, the urethane foam stock solution is injected into the inside of the bag-shaped skin material and foamed inside. Furthermore, it is for improving the adhesiveness of the resin film layer 120 and urethane foam.

  In the configuration shown in FIG. 1, the skin 110 is supplied from the supply roller 140, transported at a constant speed in the direction of the arrow by the transport means, wound around the winding roller 150, and collected. In the configuration shown in FIG. 1, the skin 110 has a certain width in the direction perpendicular to the paper surface, and the cooling roller 132 and the corona discharge generator 133 also have a depth corresponding to the width of the skin 110. ing.

  The skin 110 is made of cloth, leather or artificial leather. As the cloth, any one of tricot, jersey, woven fabric, non-woven fabric, or the like, or the like is used.

  As the resin film layer 120, a polymer material such as polyethylene, polypropylene, or polyurethane is used as a raw material.

  A procedure for forming the skin material 100 by laminating the skin 110 and the resin film layer 120 with the configuration shown in FIG. 1 will be described.

  First, the skin 110 supplied from the supply roller 140 is conveyed at a constant speed in the direction of the arrow in FIG. In this state, the resin film material extruder 131 is controlled by the control unit 160, and the resin film material 121 continuously supplies a certain amount onto the skin 110 in synchronization with the transport of the skin 110 by the transport means. To do. The resin film material extruder 131 is provided with a heating means (not shown), and the resin film material 121 is heated and stored in a liquid state. 121 is supplied on the skin 110 in a liquid state.

  Next, the resin film material 121 supplied in liquid form on the skin 110 is controlled by the control unit 160 and thinned over the entire width of the surface of the skin 110 by the cooling roller 132 that rotates in synchronization with the conveying means. The resin film layer 120 is formed by being uniformly spread and cooled. The thickness of the resin film layer 120 formed on the skin 110 can be adjusted by the distance between the transport surface that transports the skin 110 and the cooling roller 132.

  The skin 110 cooled by the cooling roller 132 and formed with the resin film layer 120 is continuously conveyed by the conveying means and passes under the corona discharge generator 133. The corona discharge generator 133 is installed so as to maintain a narrow distance from the resin film layer 120 formed on the skin 110. The corona discharge generator 133 is controlled by the control unit 160 to generate corona discharge in synchronization with the conveying means. By this corona discharge, the surface 122 of the resin film layer 120 formed of a polymer material that passes immediately below is modified and easily adsorbed, and the adhesion to the foam material can be improved.

  The skin material 100 formed by laminating a resin film layer 120 having a surface 122 that is modified and easily adsorbed on the skin 110 has a cross-sectional shape as shown in an enlarged view in FIG. The skin material 100 is controlled by the control unit 160 and is taken up and collected by a take-up roller 150 that rotates in synchronization with the conveying means.

  As described above, in this embodiment, the resin film material 121 supplied in a liquid state is used without using the wadding material (slab foam layer) supplied in a sheet form as described in Patent Documents 1 and 2. By directly supplying to 110 and forming the resin film layer 120, a manufacturing process can be simplified and both installation cost and material cost can be reduced.

  In addition, as described in Patent Document 2, when the skin material is formed only by the skin and the wadding material (slab foam layer) without using the resin film, the skin material and the wadding material are supplied in the form of a sheet, respectively. Then, it is necessary to heat and melt both sides of the wadding material with a burner, and to bond the skin material on one side and to process the other side so as to have low air permeability, and the process is complicated.

  On the other hand, according to the present embodiment, since the molten resin film material 121 is directly supplied onto the skin 110, the step of heating and melting with a burner and the step of supplying a sheet-like wadding material are unnecessary. Thus, the configuration of the equipment can be simplified and the number of processes can be reduced.

  Further, in the case of the conventional three-layer structure or two-layer structure, the structure of the equipment for laminating the three layers is complicated in order to supply the members constituting each layer as a sheet-like member. On the other hand, in the case of the skin material 100 having the two-layer structure described in this embodiment, only the skin 110 is supplied as a sheet-like member, and the material of the resin film layer 120 is the surface of the skin 110. Can be supplied in liquid form. Thereby, according to a present Example, the structure of the installation for laminating | stacking on 2 layer structure can be simplified comparatively.

  In the example shown in FIG. 1, the corona discharge generator 133 generates a discharge to modify the surface 122 of the resin film layer 120 so that it can be easily adsorbed and improve the adhesion to the foam material. As described above, instead of the corona discharge generator, a heating roller having fine irregularities formed on the surface is pressed against the surface of the resin film layer 120 to form minute irregularities on the surface 122 of the resin film layer 120, and foaming is performed. You may make it improve adhesiveness with material.

  Further, instead of the above-described corona discharge generator 133, fine irregularities may be formed on the surface of the cooling roller 132, and minute irregularities may be formed on the surface 122 of the resin film layer 120. That is, when the resin film material 121 supplied onto the skin 110 from the resin film material extruder 131 is cooled by the cooling roller 132 and the resin film layer 120 has a uniform thickness, The fine irregularities formed on the surface may be transferred to the surface of the resin film layer 120 to form fine irregularities on the surface 122 of the resin film layer 120 to improve the adhesion to the foam material.

Furthermore, in place of the corona discharge generator 133 described above, sand blasting or ozone treatment is performed to form minute irregularities on the surface 122 of the resin film layer 120 so as to improve adhesion to the foam material. Also good.
In the embodiment shown in FIG. 1, the material of the resin film layer 120 is supplied in a liquid state by a film material extruder, but instead, a sheet-like resin film sheet is used as a skin using a supply roller or the like. You may make it supply to the surface of 110. FIG.

[Production method of integral foam molding]
The example which manufactures the headrest of a passenger car is demonstrated as an example of the integral foaming molding using the skin material 100 demonstrated above.

  The skin material 100 described above is cut and sewn to form a bag-like skin member 300 for a headrest, and a cover 305 formed of a mesh-like member is attached. With the stay 340 attached to the inside of the skin member 300, a nozzle 321 for injecting a foam material is inserted into the inside of the skin member 300 formed into a bag shape from the vicinity of an opening (not shown) of the skin member 300.

  Next, as shown in FIG. 3, the stay 340 is attached, and the skin member 300 into which the nozzle 321 is inserted is sandwiched between the molds 311 and 312, and is formed into a bag shape from the urethane foam stock solution supply unit (not shown). The urethane foam stock solution 331 is supplied into the outer skin member 300. Here, the tip portion of the nozzle 321 is covered with a cover 305 formed of a mesh-like member. In FIG. 3, in order to simplify the description, the detailed configuration of the skin member 300 around the opening formed in the skin member 300 and its periphery is omitted.

  The urethane foam undiluted solution 331 ejected from the nozzle 321 into the bag-shaped skin member 300 reaches the skin member in a state where the force is weakened by hitting the cover 305. In this state, since the resin film layer 120 is formed on the inner surface of the skin member 300 (the surface in contact with the urethane foam stock solution 331), the urethane foam stock solution 331 does not soak into the skin 110.

  The urethane foam undiluted solution 331 supplied from the nozzle 321 to the inside of the skin member 300 is foamed inside the skin member 300 to form the foamed urethane 330. As shown in FIG. To form the shape of a headrest.

  In this state, the surface 122 of the resin film layer 120 is modified and easily adsorbed by corona discharge, and the adhesive property of the urethane foam 330 is improved, so that the urethane foam 330 is in close contact with the skin member 300. It has become. By using such a skin member 300, the urethane foam stock solution 331 does not soak into the skin 110.

  FIG. 5 shows a state in which the molded headrest 350 is taken out from the molds 311 and 312. As shown in FIG. 2, the surface of the skin member 300 that contacts the foamed urethane 330 is the surface 122 that has been subjected to the modification treatment of the resin film layer 120, so that the urethane foam 330 and the skin member 300 are in close contact with each other. It has become a state.

  By using such a skin member 300, the urethane foam undiluted solution 331 does not soak into the skin 110, so that the skin 110 is partially cured or foamed to the outside through a gap of a stitched portion (not shown) of the skin 110. The possibility that urethane leaks out and damages the appearance of the headrest 350 can be eliminated.

  According to the present embodiment, without using the wadding material (slab foam layer) described in Patent Documents 1 and 2, by directly forming the resin film layer 120 on the skin 110, the material cost of the headrest and Processing costs can be reduced.

  Furthermore, in the case of the conventional three-layer structure or two-layer structure, the structure of the manufacturing equipment required for handling the members constituting each layer as a sheet-like member was relatively complicated. According to the present embodiment, it is possible to relatively simplify the configuration of equipment for supplying a liquid material to the skin member supplied in the form of a sheet and laminating it in a two-layer structure.

  In the embodiment described above, the case where the headrest is formed as an example of the integral foam molded product has been described. However, the present invention can also be applied to other parts formed by integral foam molding. For example, as shown in FIG. 6, in the vehicle seat 600, in addition to the headrest 603 described above (corresponding to 350 in FIG. 5), a seat cushion 601 or a seat back 602 formed by integral foam molding, integral foam molding. It can also be applied to the armrest 604 formed by the above.

  Moreover, even if it is except a passenger car, it can apply also to the part formed by integral foam molding of a chair.

  Although the present invention has been specifically described above based on the embodiments, it is needless to say that the present invention is not limited to the embodiments and can be variously modified without departing from the gist thereof. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described.

  DESCRIPTION OF SYMBOLS 100 ... Skin material 110 ... Skin 120 ... Resin film layer 131 ... Resin film material extruder 132 ... Cooling roller 133 ... Corona discharge generator 140 ... Supply roller 150 ... Winding roller 300: skin member 311, 312 ... mold 321 ... nozzle 340 ... stay 350 ... headrest.

Claims (12)

A skin material covering a member formed of a foam material,
A skin part forming the surface of the skin material;
A skin material, comprising: a film portion made of a polymer material formed by directly laminating on the back side of the skin portion, and having undergone a modification treatment on a surface in contact with the foamed material. The skin material according to claim 1, further comprising a film portion that is supplied in a liquid state and directly laminated on the back side surface of the skin portion.   2. The skin material according to claim 1, wherein a surface of the film portion that contacts the foam material is subjected to a modification treatment with the foam material by a treatment using corona discharge. .   The skin material according to claim 1, wherein the skin portion is formed of a cloth.   The skin material according to claim 1, wherein the film part is formed of polyethylene, polypropylene, or polyurethane. A skin material covering a member formed of a foam material having a two-layer structure of a skin part and a film part formed by directly laminating and supplying the liquid part on the surface on the back side of the skin part,
The film part is formed of a polymer material, and the surface of the film part in contact with the foam material is subjected to a modification process by corona discharge.   The skin material according to claim 6, wherein the skin portion is formed of a cloth.   The skin material according to claim 6, wherein the film portion is formed of polyethylene, polypropylene, or polyurethane. A molded member formed of a foam material;
An integral foam molded article provided with a skin member covering the molded member,
The skin member is
A skin part forming the surface of the skin member;
On the back side of the skin part, comprising a film part formed by directly laminating the skin part,
The integral foam molded article, wherein the film portion is formed of a polymer material, and the surface of the film portion that contacts the molding member is subjected to a modification treatment by corona discharge.   The integral foam molded article according to claim 9, wherein the molded member is a member of a headrest of a passenger car.   The integral foam molded article according to claim 9, wherein the molded member is a member of an armrest of a passenger car.   The integral foam molded article according to claim 9, wherein the molded member is a seat cushion or a seat back member of a passenger car.

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