JP2964616B2 - Manufacturing method of skin material with uneven pattern - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for producing a skin material with a concavo-convex pattern used, for example, for seats for automobiles and furniture.

[Conventional technology]

Conventionally, as a skin material, for example, a wading urethane foam layer (urethane foam layer) is laminated on a surface layer made of natural leather such as cowskin, and this lamination is performed by sewing sewing or hand sewing. ing.

In the case of forming a concavo-convex pattern on the surface of the skin material, the two layers are similarly sewn along a desired concavo-convex pattern.

[Problems to be solved by the invention]

By the way, as described above, since these surface layers and wadding urethane foam layers (urethane foam layers) are laminated by sewing means, for example, when a part of a sewing thread is frayed, both layers are easily formed. There was a risk of peeling.

Also, as described above, in the case of forming an uneven pattern on the surface of the skin material, since the two layers are similarly formed by sewing along the desired uneven pattern, the same applies to, for example, a sewing thread. There is a possibility that the uneven pattern may easily disappear when a part is frayed, and the sewing precision of the sewing machine and the skill of hand sewing are limited, so the appearance of relatively fine patterns,
It was difficult to obtain stable quality.

Furthermore, natural leather is a relatively hard material for sewing, so this sewing work is less efficient than other shaping work with uneven patterns, and requires skill in sewing. This has been one of the factors that led to high costs.

Furthermore, in order to give a sense of volume to the unevenness pattern of the skin material, for example, a wadding urethane foam layer having a thickness of about 20 to 35 mm may be used, but the skin material is made thicker to improve the work efficiency described above. The use of a relatively thin wadding urethane foam layer, which usually has a small volume feeling, has been limited, resulting in poor design.

The present invention has been made on the background of such a conventional technique, and aims to provide a skin material in which a surface layer and a urethane foam layer are hardly peeled off, and a good work efficiency is obtained upon lamination, and In addition to these effects, the uneven pattern that appears on the surface is difficult to disappear, the appearance of relatively fine uneven patterns can be easily performed, and the uneven pattern with stable quality can be displayed. Good work efficiency can be obtained in the shaping work, and the shaping work of the uneven pattern can be easily performed without requiring skill, thereby producing a skin material with the uneven pattern on the surface at low cost. It is an object of the present invention to provide a method for producing a skin material which is capable of producing a skin material which is rich in design and has a good texture.

[Means for solving the problem]

The present invention forms a skin material by laminating a urethane foam layer having a thickness of 5 to 35 mm at a temperature of 10 to 70 ° C. at least on a surface layer made of natural leather via an adhesive layer made of a water-based adhesive, The skin material is heated and pressurized by using an upper mold and a lower mold having a lower blade and an upper mold in which a pressing blade is implanted and a heat insulating material is stored in a gap of the pressing blade, and the surface of the skin material is heated. The present invention provides a method for producing a skin material with a concavo-convex pattern, characterized in that a concavo-convex pattern is formed on the surface material.

[Action]

The skin material with a concavo-convex pattern of the present invention is obtained by sequentially laminating a urethane foam layer via an adhesive layer made of a water-based adhesive on at least a surface layer made of natural leather, so that the surface layer and the urethane foam layer are It is difficult to peel off, and good working efficiency can be obtained in laminating work.

Further, the method for producing a skin material with an embossed pattern of the present invention comprises, at least on a surface layer made of natural leather, an urethane foam layer laminated at a temperature of 10 to 70 ° C via an adhesive layer made of an aqueous adhesive. Since the material is formed and the surface of the skin material is formed with an uneven pattern using a molding die, in addition to the above-described effects, the uneven pattern appearing on the surface is hard to disappear,
The appearance of relatively fine uneven patterns can be easily achieved, the appearance of uneven patterns with stable quality can be achieved, and good work efficiency can be obtained in the shaping work of uneven patterns. Since the shaping work can be done easily without skill, it is possible to produce at low cost a skin material with an uneven pattern on the surface, and it has rich design and good texture. A method for producing a patterned skin material can be provided.

〔Example〕

Hereinafter, a method for producing a skin material with a concavo-convex pattern according to an embodiment of the present invention will be described with reference to the drawings.

In the description of the embodiments, a method for producing a skin material with a concavo-convex pattern applied to a seat of an automobile seat will be described as an example.

A skin material 10 according to an embodiment of the present invention shown in FIG. 1 includes a surface layer 11 made of cowhide (natural leather), an adhesive layer 12 made of an aqueous adhesive, a wading urethane foam layer (urethane foam layer) 13, and And the backing layer 14 are sequentially laminated.

As the surface layer 11, besides cow skin of the embodiment, horse skin,
Natural leather, which is generally used as the surface layer 11 of the skin material 10 such as deer skin, sheep skin, and mink skin, can be adopted.In the embodiment, a cow skin having a fine embossed pattern formed on the surface is used. However, it is not necessary to limit to this.

The thickness of this surface layer 11 is 0.5 to 4.0 mm, particularly 1.0 to 2.5 mm
If it is less than 0.5 mm, the feeling as natural leather is poor, the strength is weakened and the durability is poor, while 4.
If it exceeds 0 mm, the hand becomes hard and the handling during molding becomes poor.

Although the elongation percentage of the surface layer 11 in this embodiment is 60%, it is not necessary to limit the elongation percentage to 40%.
The above conditions are preferable because a good voluminous feel of the surface material 10 can be obtained.

Although the surface layer 11 of this embodiment is cut into an optimum yield shape for a desired shape, it is not necessarily limited to this.

As the aqueous adhesive used for the adhesive layer 12, for example, containing water, natural rubber-based, polyolefin-based,
In addition to an emulsion adhesive or a latex adhesive made of a natural resin such as a synthetic rubber, an acrylic resin, a urethane resin, or a vinyl acetate resin, or a synthetic resin, an ordinary water-based adhesive can be used. In this embodiment, an acrylic / ethylene-modified resin-based emulsion adhesive having a solid content of 50% by weight and a water content of 50% by weight is used.

Basis weight of the adhesive layer 12, although the 75 g / m ² in terms of solid content in this embodiment, need not necessarily be limited to, 20 to 200 g / m ^2, especially 50 to 100 g / m ² Preferably
If it is less than 20 g / m ² , the adhesiveness is poor and the durability is poor.
If it exceeds 200 g / m ² , the feeling is impaired by the solidified adhesive.

As a method of laminating the adhesive layer 12, for example, a general method of applying an adhesive such as a spray method, a roll coating method, a brush coating method, and a dipping method can be adopted. In the embodiment, a roll coating method is adopted.

As the wading urethane foam layer 13, a material cut out from a soft slab urethane foam to a predetermined thickness is used.

Although the thickness of the wadding urethane foam layer 13 of this embodiment is 25 mm, it is not necessarily limited to this, but it can be appropriately selected in order to give a desired texture, a design such as a sense of volume, but in a range of 5 to 35 mm. is there.

The wading urethane foam layer 13 is cut according to the shape of the surface layer 11.

As the backing layer 14, although a nylon non-woven fabric is used, for example, a non-woven fabric such as polyester, knitted fabric,
A commonly used backing layer 14 can be used. In addition, the skin material 10 may be a laminate of at least the surface layer 11, the adhesive layer 12, and the wading urethane foam layer 13, and the backing layer 14 is not necessarily required.

As a method of laminating the backing layer 14, a general laminating method such as laminating the backing urethane foam layer 13 at a predetermined time via an adhesive can be adopted, but the wading urethane foam layer 13 is used in advance. It is preferable that the layers are integrally laminated because high production efficiency can be obtained.

Note that the display material 10 may be one in which a very thick cushion body is integrated on the back surface side.

The skin material 10 of this embodiment is obtained by applying the adhesive layer 12 to the surface of the wading urethane foam layer 13 on which the backing layer 14 is laminated, and then including the adhesive layer 12 on the adhesive layer 12. The surface layer 11 is placed in a wet state in which the water content is 30% by weight or more, preferably 50% by weight or more, and is net-pressed for 3 minutes in a 50 ° C. atmosphere at a pressure of 0.5 g / cm ^2. It has been subjected to lamination processing.

If the adhesive layer 12 is laminated in a state where the water content is less than 30% by weight, the adhesive effect is weakened and a partial floating due to poor adhesion occurs, which is not preferable.

In addition, the temperature at the time of lamination is not limited to 50 ° C, is in a range of 10 to 70 ° C, preferably in a range of 30 to 60 ° C. 70
When the temperature exceeds ℃, it is not preferable because it has an adverse effect on the grain of natural leather.

Further, the pressure at the time of the lamination does not need to be limited to 0.5 g / cm ² .

The backskin side of the natural leather, which is the surface of the surface layer 11 on the side of the adhesive layer 12, is excellent in water absorption, so it rapidly absorbs the moisture contained in the adhesive layer 12 during lamination, and Can be integrated by press bonding.

The order of lamination of each layer 11,... 14 of the skin material 10 is not limited to the order described above.For example, after the adhesive layer 12 is applied to the back surface of the surface layer 11, the wadding urethane foam layer 13 is formed. Other lamination orders such as pressure bonding may be used.

As described above, since the wading urethane foam layer 13 is laminated on the surface layer 11 with the adhesive layer 12 interposed therebetween, the surface layer 11 and the wadding urethane foam layer 13 are not easily separated, and the laminating operation is also easy. Good work efficiency can be obtained.

Next, in the embodiment of the present invention, the skin material 10 is shown in FIGS.
As shown in FIGS. 5 to 7, the surface material 10a of the skin material 10 has a large rhombic concave portion (irregular pattern) 10b and a seating seat (not shown) as shown in FIGS. A peripheral edge covered portion 10c adapted to the shape of the curved peripheral edge 31 of the seat body 30 shown in FIG. 8 is formed.

The molding die 20 includes a lower die 21 as shown in FIGS.
And the upper mold 22, and the lower mold 21 is provided on the substrate 211,
The lower mold body 213 which is extremely thick and has a curved portion 212 shown in FIG. 3 and FIG. 4 formed at one end with the shape of the curved peripheral portion 31 of the seat seat body 30 shown in FIG. On the other hand, the upper die 22 has a width of 6 m shown in FIGS. 2 to 4 which forms the contour of the skin material 10 shown in FIG.
m-shaped outer peripheral pressing blade 222 and a diamond-shaped pressing blade 22 for forming a 1-mm-wide rhombic concave portion 10b arranged in a diamond shape in the outer peripheral pressing blade 222.
3 is planted. In addition, these outer peripheral pressing blades 222
The width of the rhombic pressing blade 223 and the number of the rhombic pressing blades 223 are not limited.

As the lower die body 213, for example, a mold made of aluminum or iron can be adopted, and as a material of the outer peripheral pressing blade 222 and the rhombic pressing blade 223 of the upper die 22, for example, there is little thermal expansion such as iron and wear resistance. Materials having properties can be adopted.
The lower mold body 213 of this embodiment is made of aluminum, while the outer peripheral pressing blade 222 and the rhombic pressing blade 223 are made of iron.

Further, in this embodiment, as shown in FIG. 4, the fine embossed pattern formed on the surface of the surface layer 11 shown in FIG. For example, a heat insulating material 40 made of a glass wool mat, rigid or semi-rigid urethane foam or the like and shown in FIG. Therefore, when the skin material 10 shown in FIG. 1 is fitted and shaped by the upper and lower dies 21 and 22 shown in FIGS. 2 to 4, the surface of the surface layer 11 shown in FIG.
By covering with the heat insulating material 40 shown in the figure, the heat of the upper mold 22 is not directly transmitted to the surface of the surface layer 11 shown in FIG. However, there is no danger of the diamond-shaped recess 10b being extinguished by heat at the time of shaping as shown in FIG.

The pressing condition of the skin material 10 by the molding die 20 is preferably a temperature of 100 to 190 ° C., particularly preferably 130 to 170 ° C., and if the temperature is lower than 100 ° C., the laminated wadding urethane foam is not compressed and is not formed into a predetermined shape. On the other hand, when the temperature exceeds 190 ° C., the pressed portion of the leather is damaged.

An example of the shaping of the skin material 10 shown in FIG. 5 using the molding die 20 shown in FIGS. 2 to 4 is shown in advance in the lower mold (urethane foam) shown in FIGS. 3 and 4. Layer side) 21 lower mold body 213 to 160 ° C, while upper mold (surface layer side)
The outer peripheral pressing blade 222 and the rhombic pressing blade 223 of 22 are heated to 140 ° C.
The skin material 10 shown in FIG. 1 on which the lamination is performed is placed between the upper and lower molds 21 and 22. Thereafter, the upper mold 22 is pressed for 3 minutes to remove the mold material, and then the skin material 10 is removed. By trimming along the embossed line formed by the outer peripheral pressing blade 223,
As shown in FIG. 5, a skin material 10 in which a diamond-shaped concave portion 10b is formed on a surface 10a and a peripheral edge covered portion 10c conforming to the shape of the curved peripheral portion 31 of the seat body 30 shown in FIG. Is obtained.

The skin material 10 obtained in this manner is obtained by sewing the gusset material 50 and the sod material 60 individually prepared at predetermined positions,
With a tension that does not impair the appearance of the seat, the curved peripheral portion 31 is wound around the peripheral portion covering portion 10c, and is covered on the seat body 30. For this reason, the seat body
Good work efficiency can be obtained at the time of mounting on the seat 30, and a good voluminous feel, designability such as appearance, and texture can be exhibited on the manufactured seat body 30.

After laminating the skin material 10 under the conditions of 10 to 70 ° C., the surface 10a of the skin material 10 is formed by using the forming die 20 shown in FIGS. , The pattern of the diamond-shaped recess 10b appearing on the surface 10a is not easily erased, and the pattern is formed by the molding die 20 shown in FIGS. The appearance of a relatively fine uneven pattern other than the diamond-shaped recess 10b can be easily made, and the appearance of the diamond-shaped recess 10b with stable quality can be made. Further, the lower mold 21 and the upper mold 22 shown in FIGS. The shape can be formed by the efficient work of heat-compression bonding in the diamond-shaped recess 10 shown in FIG.
A good work efficiency can be obtained in the shaping work of b, and the shaping work of the diamond-shaped recess 10b can be easily performed without skill, so that the surface material 10 having the diamond-shaped recess 10b formed on the surface 10a can be obtained. Can be produced at a low cost, and a voluminous skin material 10 using the thick wadding urethane foam layer 13 shown in FIG. 1 can be easily obtained. A good skin material 10 can also be obtained.

Although the embodiment of the present invention has been described above, the present invention is not limited to this embodiment, and any change in design without departing from the scope of the present invention is included in the present invention.

For example, in the embodiment, a skin material used for a seat of an automobile seat is taken as an example, but it is not necessarily limited to this, and for example, a seat of an automobile seat or a seat for furniture. Can be adopted.

Further, a skin material in which at least a surface layer made of natural leather, an adhesive layer made of a water-based adhesive, and a urethane foam layer are sequentially laminated has a surface in which an uneven pattern is previously formed on the surface, and after lamination. And those having a surface with a concavo-convex pattern.

〔The invention's effect〕

Since the present invention is such that at least a surface layer made of natural leather, an adhesive layer made of a water-based adhesive, and a urethane foam layer are sequentially laminated, the surface layer and the urethane foam layer are hardly peeled off. Also, good working efficiency can be obtained in the laminating operation.

Further, the method for producing a skin material with a concavo-convex pattern of the present invention comprises forming a skin material by laminating a urethane foam layer on at least a surface layer made of natural leather via an adhesive layer made of a water-based adhesive. This skin material is laminated under the condition of 10 to 70 ° C., and then the surface material of the skin material is formed with an uneven pattern using a molding die, in addition to the effects described above,
Uneven patterns appearing on the surface are not easily erased, relatively fine uneven patterns can be easily exposed, and uneven patterns with stable quality can be displayed. Efficiency is also obtained, and the shaping work of this uneven pattern can be easily performed without skill, so that a skin material with the uneven pattern formed on the surface can be produced at low cost, and the design can be improved. The effect is obtained that it is possible to provide a display material with a concavo-convex pattern that is abundant and has a good feeling.

[Brief description of the drawings]

FIG. 1 is an enlarged sectional view of a skin material according to an embodiment of the present invention, FIG. 2 is a plan view of a molding die for forming an uneven pattern on the surface of the skin material of the embodiment, and FIG. FIG. 4 is a cross-sectional view taken along the line IV-IV of FIG. 2, FIG. 5 is a perspective view of the skin material with a concavo-convex pattern of the embodiment, FIG. 6 is a cross-sectional view taken along the line VI-VI of FIG. FIG. 7 is a sectional view taken along the line VII-VII of FIG. 5, and FIG. 8 is a perspective view showing a state of use of the skin material with a concavo-convex pattern of the embodiment. 10; skin material 10a; surface 10b; diamond-shaped concave portion (irregular pattern) 11; surface layer 12; adhesive layer 13; wading urethane foam layer (urethane foam layer) 20; molding die

Claims (1)

(57) [Claims] 1. A skin material is formed by laminating a urethane foam layer having a thickness of 5 to 35 mm at a temperature of 10 to 70 ° C. on at least a surface layer made of natural leather via an adhesive layer made of a water-based adhesive. The skin material is heated and pressurized by using an upper mold and a lower mold having a lower blade and an upper mold in which a pressing blade is implanted and a heat insulating material is stored in a gap of the pressing blade, and the skin material is pressed. A method for producing a skin material with an uneven pattern, characterized by forming an uneven pattern on the surface.