JP3034360B2 - Method of manufacturing sheet using adhesive - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a vehicle seat and the like, and more particularly to a method for manufacturing a sheet in which a cushion pad and a skin material are integrated with an adhesive.

[0002]

2. Description of the Related Art Conventionally, in a sheet using an adhesive, a skin material and a cushion pad are arranged between upper and lower dies, and the adhesive is interposed between the skin material and the cushion pad. They are integrally joined, and a hot-melt adhesive or a solvent-type adhesive in the form of an adhesive film has been used as the adhesive.

[0003] However, when a hot melt type adhesive is used, high heat resistance is required and when bonding,
There is a problem that a higher temperature is required, and a thermal load is applied to the skin material and the cushion pad. In the case of the solvent-type adhesive, an adhesive force is already generated when the adhesive is applied. In addition, there is a problem that the cushion pad and the skin material are joined at the stage where they come into contact with each other.

[0004] Further, in joining the skin material and the cushion pad, the upper and lower molds are used to arrange the skin material along one mold, and the cushion pad is arranged to face the other mold. In addition, an adhesive is applied to at least one of the opposing surfaces of the skin material, and pressure and heat are applied thereto.

However, in the technique of separately arranging the skin material and the cushion pad in the upper and lower molds, in order to improve the molding cycle, one of the upper and lower molds is configured to heat and cool. Heating and cooling with the same mold when bonding the skin material and the cushion pad in this way means heating and cooling the mold itself, which in turn lengthens the molding cycle and lowers the production efficiency. Furthermore, the cushion pad and the skin material are heated, cooled, and pressed by the same mold. In the case of a skin material with a brushed surface or a skin material using leather, the hair may fall down, and the processing heat is applied to the leather. Is not preferred.

An object of the present invention is to provide a method of manufacturing a sheet using an adhesive which can shorten the molding cycle in the bonding step and can be formed without applying heat to the skin material.

[0007]

According to a first aspect of the present invention, a skin material is attached to one of the upper and lower mounting dies, a cushion pad is attached to the other mounting dies, and the skin material and the cushion pad are reactive hot melt bonded. In a method of manufacturing a sheet which is bonded to each other by an agent, an application step of applying an adhesive to a cushion pad, and the adhesive application surface of the cushion pad to which the adhesive is applied is directed to the other mold to one mounting mold. An assembling step of attaching the skin material to the other mounting mold consisting of a cooling press-fitting type and a heating step of heating the adhesive application surface of the cushion pad with a heating mold,
After the heating step, a cooling and pressing step of cooling while pressing to the cushion pad side together with the skin material by a cooling and pressing mold,
The method for producing a sheet using an adhesive characterized by comprising: The present invention is particularly suitable when the skin material does not have air permeability.

A third aspect of the present invention is a method of manufacturing a sheet, comprising bonding a skin material and a cushion pad to each other with a reactive hot melt adhesive by using a cushion pad mounting type and a cooling pressure bonding type. A coating step of applying an adhesive, a cushion pad mounting step of mounting the adhesive on the cushion pad with the adhesive applied surface of the cushion pad facing the cooling pressure bonding type, and a cushion pad mounting type and a cooling pressure bonding type. A skin material mounting step of mounting a skin material on a movable skin material mounting frame disposed on the surface, a heating step of heating the adhesive-applied surface of the cushion pad by a movable heating device, and then moving the heating device; A skin material arranging process in which the material mounting frame is moved and arranged between the cushion pad mounting type and the cooling / compression bonding type; A cooling crimping step of cooling under pressure to the cushion pad side with the skin material after the wood disposing step and the heating step by cooling crimping type, a method for manufacturing a sheet using an adhesive agent characterized in that it consists of.

The reactive hot melt in each of the above inventions is, for example, one having an active double bond during hot melt bonding and being cured by ultraviolet rays, electron beams, etc., and having an epoxy group and a latent curing material. Thermosetting, NCO
And a group which has an SH (OR) ₃ group and is cured by moisture, a group which has an SH group and a metal oxide catalyst and is cured by oxygen, etc., and particularly a urethane-based wet-curable adhesive. Is preferred.

[0010]

An embodiment of the present invention will be described below with reference to the drawings. The members, arrangements, and the like described below do not limit the present invention, and can be variously modified within the scope of the present invention. FIGS. 1 to 6 show a first embodiment.
1 shows an embodiment for specifically describing the invention described in (1), and the seat in this embodiment will be described by taking a vehicle seat as an example. The sheet S includes a skin material H made of non-breathable leather or the like, and a cushion pad P. The skin material H is formed in a predetermined shape in advance by sewing or the like. Coated with material H. The cushion pad P and the skin material H are integrally formed by an adhesive A.

The method of manufacturing the sheet S using the adhesive A in this embodiment includes the following steps. Cushion pad P
A coating step 10 of applying an adhesive A to the cushion pad P to which the adhesive A has been applied is attached to one of the mounting molds with the adhesive applied surface facing the other mold, and the other is attached to the other mounting mold composed of a cooling pressure bonding mold. An assembling step 20 for attaching a skin material;
A heating step 30 for heating the adhesive-applied surface of the cushion pad P with a heating die, and a cooling / compression bonding step 40 for cooling the surface of the cushion pad P together with the skin material H by using a cooling / compression die after the heating step.

In the coating step 10 of applying the adhesive A to the cushion pad P in this embodiment, as shown in FIG. 2, the molten reactive hot melt adhesive A is applied to the cushion pad P by a special spray gun G. It is evenly applied to the joint surface 11 of the skin material H. Examples of the reactive hot melt adhesive A used in the present example include those which have an active double bond during hot melt bonding, are cured by ultraviolet rays, electron beams, etc., and have epoxy groups and latent curing materials. Examples thereof include those which are thermally cured, those which have NCO groups and Si (OR) ₃ groups and are cured by moisture, those which have SH groups and metal oxide catalysts and are cured by oxygen. Wet-curing adhesive A is preferred. Specifically, a moisture-curable hot-melt adhesive A containing a polyester-based isocyanate prepolymer as a main component, and a commercially available one can be used (for example, “Hybon 4832” registered trademark, Hitachi Chemical Co., Ltd.) ).

When the reactive hot melt adhesive A is applied to the cushion pad P as described above, the adhesive A is cooled and solidified immediately after the application, so that it can be conveyed. Further, the adhesive A need not be applied to the entire surface of the cushion pad P, but may be applied only to the reverse R (R) portion (that is, the concave portion) of the cushion pad P.

Next, after the application step 10 of applying the adhesive A to the cushion pad P as described above, an assembly step 20 is performed. The assembling step 20 of this example is performed by attaching the skin material H and the cushion pad P to the upper and lower molds. That is, as shown in FIG. 3, the cushion pad P is first mounted on the cushion pad mounting die 21. At this time, the surface opposite to the application surface (bonding surface) 11 of the adhesive A is attached to the cushion pad attachment die 21. Next, as shown in FIG.
The skin material H is attached to the lower crimping die 51. At this time, the skin material H is turned upside down and assembled so that the surface of the skin material H contacts the cooling crimping die 51. In addition, skin material H
Is fixed by a fixing tool (not shown) such as a needle or a hook. The skin material H of this example is formed in advance so as to conform to the shape of the cushion pad P, but may be a skin material H that is not preformed.

Next, as shown in FIG. 5, a heating step 30 for heating the adhesive applied surface of the cushion pad P assembled in the assembling step 20 by a heating die 41 is performed. That is, the heating mold 41 of the present example is a hollow box configured to be slidable in the left-right direction (FIGS. 1 and 5), and the mold surface 42 of the heating mold 41 has a surface shape ( (The shape of the cushion pad P), and a plurality of through holes 43 are formed in the mold surface 42. A connecting pipe 44 is attached to a predetermined position on the side of the heating mold 41, and steam or hot air is introduced from the connecting pipe 44 to the heating mold 41. In this example, the gap (clearance) between the cushion pad P and the heating mold 41 is about 3 to 20 mm, and the temperature is 1
Heat at 00 ° C for about 20 seconds. Therefore, the heating die 41 can be heated by bringing the heating die 41 close to the cushion pad P, and the reactive hot melt adhesive A applied to the cushion pad P can be reactivated and melted. After melting the reactive hot melt adhesive A in this manner, the steam or hot air of the heating mold 41 is stopped, and the heating mold 4 is melted.
Slide 1 Since the reactive hot melt is used as the adhesive in this manner, heat resistance is generated after the adhesive reaction, and the melting temperature of the adhesive (60 in the case of the above embodiment).
° C). The through hole 4 of the heating mold 41
By disposing a cushioning material such as a skeleton foam on the upper surface of 3, the cushion pad P can be heated uniformly.

Next, after the heating step 30, the skin material H
A cooling press bonding step 40 is performed in which cooling is performed while pressing the surface of the skin material H from the surface of the skin material H to the cushion pad P side by the cooling press bonding die 51 to which is attached. The cooling pressure bonding mold 51 of this example has a box shape, and the mold surface 52 has a mold surface shape conforming to the surface shape of the sheet S (the shape of the skin material H and the cushion pad P on the skin material H side). . This mold surface 52 has a plurality of through holes 5.
3 is formed, and at a predetermined position of the lateral force of the cooling / compression bonding mold 51,
A connecting pipe 54 and a cold water pipe 55 are attached. Cold water pipe 5
Cool water is circulated through 5, air is introduced from the connecting pipe 54, and thereby cooling air is ejected from the through-hole 53. Then, the cooling pressure bonding mold 51 is urged toward the cushion pad P with a predetermined pressure to tighten the pressure, and air is ejected from the through-hole 53 to cool. The pressure in this example is 0.0
The pressure is 5 kg / cm ² , and the plurality of through holes 53 formed in the mold surface 52 of the present example has a hole diameter of 1 to 2 m.
m, the gap (pitch) is formed to be 20 to 50 mm.
In this example, the air flow rate is about 200 l / min in the case of air blow.

In the cooling press-bonding mold 51, an example has been described in which air is introduced into the cooling press-bonding mold. However, it is also possible to adopt a configuration in which air is sucked. Next, the mounting die 21 in the assembly process 20
The cushioning pad P and the skin material H are removed from the base material and assembled to a seat frame (not shown).
Terminal processing.

FIG. 7 shows another embodiment of the cooling / compression bonding step 40. In this example, the air suction means 57 is attached to the mounting mold 56 on the cushion pad P side used in the assembling step 20.
And using the apparatus shown in FIG. 6 as a cooling press bonding type. That is, the mounting die 56 is formed as a hollow box, and a large number of air holes 58 are formed in the die surface 57 that comes into contact with the cushion pad P of the mounting die 56. (Not shown)). With the configuration as in the present example, excess moisture in the cushion pad P can be removed by suction.

FIG. 8 shows an embodiment for specifically explaining the invention described in claim 3. In this invention, a skin material and a cushion pad are connected by using a cushion pad mounting type and a cooling pressure bonding type. This is a method for producing a sheet which is bonded to each other by a reactive hot melt adhesive. The same steps and the like as those in the embodiment shown in claim 1 are denoted by the same reference numerals, and description thereof will be omitted.

The method for manufacturing the sheet S using the adhesive A in this embodiment includes the following steps. That is, a coating process of applying the adhesive A to the cushion pad P, and a cushion pad mounting process of mounting the adhesive A on the cushion pad mounting die 21 with the adhesive applied surface of the cushion pad P facing the cooling / compression die 51. A skin material mounting step of mounting the skin material H on a movable skin material mounting frame disposed between the cushion pad mounting die 21 and the cooling and pressing die 51, and a heating device capable of moving the adhesive applied surface of the cushion pad P After heating by heating, the heating device is moved, the heating device is moved, the skin material mounting frame is moved, and the skin material arranging process is arranged between the cushion pad mounting die 21 and the cooling and crimping die 51; This is a cooling / compression step in which the cooling / compression bonding is performed while pressing the surface of the cushion material P together with the skin material H by the cooling / compression die 51 after the step.

The coating step 10 in this embodiment is the same as in the embodiment shown in FIG. The cushion pad mounting die 21 is the same as FIG. 1 except for the difference between the upper and lower die. Therefore, these descriptions are omitted.

In the skin material mounting step in this embodiment, a skin material mounting frame 61 made of a frame that can slide is used. The skin material mounting frame 61 is arranged between the cushion pad mounting die 21 and the cooling and pressing die 51. Then, the skin material H is attached to the skin material mounting frame 61, and the skin material H is stretched and held by a known skin material clamp member.

Next, a heating step is performed. That is, the adhesive application surface of the cushion pad P is heated by the heating device 71. The heating device 71 of the present example heats only the adhesive-applied surface side of the cushion pad P, and is performed by a known means such as steam, hot air, or the like. It is configured to be able to move. After heating, the heating device 71 is moved out of the range of the cushion pad mounting die 21 and the cooling and pressing die 51.

Next, in a skin material arranging step, the skin material mounting frame 61 is moved to be disposed between the cushion pad mounting die 21 and the cooling and pressing die 51. The order of the heating step, the skin material attaching step, and the skin material arranging step may be the same.

After the skin material arranging step and the heating step, a cooling / compression step of cooling while applying pressure to the cushion pad P together with the skin material H by the cooling / compression die 51 is performed. The operation of the cooling / compression bonding process is the same as that of the embodiment shown in FIGS. 1 to 6 except that the mold is upside down, and therefore the description thereof is omitted.

[0026]

As described above, according to the present invention, the heating and cooling time can be shortened and the processing cycle can be shortened by separately using the heating mold and the cooling and pressure bonding mold. Then, since compression bonding is performed by a cooling compression bonding type, cooling compression bonding is performed, and deterioration of the skin material such as falling of the hair of the skin material can be prevented. In particular, because it can be manufactured without applying heat to the skin material,
This is suitable when leather or the like is used for the skin material.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram showing a manufacturing apparatus according to an embodiment of the present invention.

FIG. 2 is an explanatory view showing the steps of the embodiment according to the first aspect of the present invention.

FIG. 3 is an explanatory view showing the steps of the embodiment according to the first aspect of the present invention.

FIG. 4 is an explanatory view showing the steps of the embodiment according to the first aspect of the present invention.

FIG. 5 is an explanatory view showing the steps of the embodiment according to the first aspect of the present invention.

FIG. 6 is an explanatory view showing the steps of the embodiment according to the first aspect of the present invention.

FIG. 7 is an explanatory view similar to FIG. 6, showing the steps of another embodiment of the present invention.

FIG. 8 is a schematic configuration diagram showing a manufacturing apparatus according to an embodiment of the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 coating process 20 assembling process 21 mounting die 30 heating process 40 cooling and pressing process A reactive hot melt adhesive H skin material P cushion pad S sheet

Continuation of the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B68G 7/05 B29C 65/42 B68G 65/02 B29L 31:58

Claims (3)

(57) [Claims] 1. A method of manufacturing a sheet, comprising: attaching a skin material to one of upper and lower mounting dies, attaching a cushion pad to the other mounting die, and bonding the skin material and the cushion pad to each other with a reactive hot melt adhesive. At
An application step of applying an adhesive to the cushion pad, and mounting the adhesive applied surface of the cushion pad to which the adhesive has been applied to the other mold with the adhesive applied surface facing the other mold; An assembling step of mounting the material, a heating step of heating the adhesive-applied surface of the cushion pad with a heating mold, and a cooling and pressing step of cooling while pressing the skin material together with the skin material by a cooling and pressing mold after the heating step. And a method for producing a sheet using an adhesive. 2. The method for producing a sheet using an adhesive according to claim 1, wherein the skin material has no air permeability. 3. A method of manufacturing a sheet, comprising bonding a skin material and a cushion pad to each other with a reactive hot melt adhesive by using a cushion pad mounting type and a cooling pressure bonding type, wherein an adhesive is applied to the cushion pad. A cushion pad mounting step of mounting the adhesive on the cushion pad mounting mold with the adhesive applied surface of the cushion pad facing the cooling press bonding mold, and a movable pad disposed between the cushion pad mounting mold and the cooling press bonding mold A skin material mounting step of attaching the skin material to a possible skin material mounting frame, a heating step of heating the adhesive application surface of the cushion pad by a movable heating device, and then moving the heating device; and A skin material arranging step that is movable and arranged between the cushion pad mounting type and the cooling pressure bonding type,
A method for producing a sheet using an adhesive, comprising: a cooling / compression-bonding step of cooling the skin material together with the skin material while pressing the cushioning material together with the skin material using a cooling / compression-molding method after the skin material arrangement step and the heating step.