JP3242984B2 - Manufacturing method of laminate - 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 producing a laminate for use as an intermediate product such as seats, cushions, sofas or clothes for vehicles and furniture, for example, using leather as a skin and urethane foam as a base material. The present invention relates to a method for producing an intermediate product in which a skin and a substrate are partially adhered.

[0002]

2. Description of the Related Art In a conventional leather sheet, for example, a foam and a leather are finely cut for each part having a predetermined shape, the foam and the leather are overlapped for each part, and a peripheral portion thereof is machined. Was sewn (temporary stitch) to produce an intermediate product. Such an intermediate product is arranged at a predetermined position on a seat pad, and the periphery of each intermediate product is sewn (final stitch) to produce a leather seat.

[0003] When the intermediate product is as thick as about 50 to 100 mm, it has been known that a part of the constituent material is melted and bonded by high frequency or hot pressing.

[0004]

The sewing by the sewing machine is as follows.
It seems very easy to see how the sewing is done freely, but as it can be inferred from the fact that there are many types of sewing machines themselves, the operation requires skill and there is a problem of labor shortage or an increase in man-hours. was there. Further, since the foam and the leather as the skin have different properties such as elongation and softness, it takes time to sew in the temporary sewing process. In particular, when leather is used, it is harder than ordinary woven fabrics, and the quality varies greatly, and it has been very difficult to sew such leather with a soft and stretchable foam. When an intermediate product is manufactured by high frequency or hot pressing, a mold having that shape is required to partially bond a shape such as a straight line. If a mold is made, a large number of products having the same shape can be produced accurately, but a shape that can be freely formed cannot be immediately produced as in the case of sewing with a sewing machine. In addition, it takes time to design and create a mold, and there is an inconvenience that it takes too much cost and time to create a small number of various shapes.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method capable of overcoming the difficulty of the conventional basting process and manufacturing a small number of various shapes easily and inexpensively.

[0006]

SUMMARY OF THE INVENTION In order to achieve the above-mentioned object, the present invention provides a method for producing a thermoplastic resin at least at a portion where bonding is desired between a base material made of a material having thermal conductivity and a skin. A step of interposing, and covering a portion other than a portion corresponding to a portion of the base material to be heated or a base material to be adhered onto the skin and a surface skin made of a material having thermal conductivity, and shaping and shaping the heat. a step of mounting easy urethane foam or melamine form of insulation, the thermoplastic substrate which is interposed resin and the skin and the heat insulating material was set in a hot press with heating from a heat insulating material side between It comprises a step of pressurizing the whole, and a step of cooling and solidifying the thermoplastic resin taken out of the hot press machine and melted to bond the base material and the skin.

[0007]

In the present invention, when a laminate as an intermediate product, for example, an intermediate product of a leather sheet is manufactured, the thermoplastic resin interposed between the leather and the foam is heated and melted in place of the step of temporarily sewing leather and foam. The solidification by cooling allows the leather and the foam to be bonded together, so that a laminate as an intermediate product can be easily and quickly manufactured. In addition, at the time of heating, because a heat insulating material such as melamine foam is interposed,
At the location covered with the heat insulating material, heat is blocked, and it is possible to securely adhere only to the location to be bonded. Further, the heat insulating material such as melamine foam can be easily processed into a shape according to the shape of the intermediate product, and a free shape can be immediately bonded as in the case of sewing. . Particularly, a melamine foam formed by thermocompression molding is thin, has excellent heat insulating properties, and has good durability.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. In the embodiment shown in FIG. 1, a thermoplastic resin 3 is interposed at least between the base material 1 and the skin 2 where bonding is to be performed, and the base material 1 and the skin 2 to be bonded on the skin 2 are bonded together. A heat insulating material 4 such as urethane foam or melamine foam, which is easy to shape and is placed, is placed on a portion other than the portion corresponding to the portion to block heat. FIG. 2 shows a state where the heat insulating material 4 is placed on the skin 2. The substrate 1, the thermoplastic resin 3, the skin 2, and the heat insulating material 4 are set in a heat press 5 and heated from the heat insulating material 4 side and pressurized as a whole. When the hot platen 6 of the hot press 5 is pressed against the heat insulating material 4, the hot platen 6
Heat passes through the portion without the heat insulating material 4 and is transmitted from the skin 2 made of a material having thermal conductivity to the thermoplastic resin 3. The heated thermoplastic resin 3 melts. By removing the pressure bonding of the hot platen 6, the molten portion of the thermoplastic resin 3 is solidified and the skin 2 is bonded to the base material 1.

The base material 1 is preferably a synthetic resin foam such as urethane foam having a good cushioning property, a fiber aggregate, or the like. As the skin 2, a textile fabric such as a woven fabric, a knitted fabric, or a non-woven fabric, and leather are used. As the thermoplastic synthetic resin 3 to be interposed between the skin 2 and the substrate 1, a film-like, non-woven, powdery or the like is used, and is appropriately selected in consideration of workability and the like. However, since the thermoplastic synthetic resin 3 remains after molding in a portion that is not heated, if it is inconvenient to remain as a product, the thermoplastic synthetic resin 3 is fixed to the base material 1 or the like before molding beforehand. Preferably, the powdery hot melt is randomly or dot-coated on the substrate 1 or the like. In addition, in order to improve the accuracy of the range of the bonded portion, it is preferable that the heat insulating material 4 has a small thickness. Further, a material which is compressed at the time of molding and does not impair heat insulation even if the thickness at normal time is large is preferable. On the other hand, foams such as felt and urethane foam are preferable because they can be easily cut into various shapes by scissors or the like. Further, heat resistance is required so that the performance does not change even if molding is performed many times, and melamine foam is particularly preferable as the optimal heat insulating material 4 including this point. Further, as a method for improving the durability, it is preferable to use a melamine foam obtained by hot compression molding. As melamine foam, Japanese Patent Publication No. 63-8
The use of those described in Japanese Patent No. 976 has extremely good heat resistance and excellent durability. The physical properties of the melamine foam (thickness 10 mm) described in this publication are as follows.
6 g / cm ³ , tensile strength 1.66 kg / cm ² , elongation at break 40%, tear strength 0.33 kg / cm, and thermal conductivity (24 ° C.) 0.0293 Kcal / mh ° C. When the melamine foam having such physical properties was subjected to thermocompression molding and made thinner before use (a 10 mm thickness was compressed to a 3 mm thickness), sag was reduced and the heat insulating performance was not changed. The tear strength of this hot-pressed melamine foam was 0.73 kg / cm. 20
When a sheet having a thickness of 3 mm was thermocompression molded to 3 mm, the tear strength was 1.73 kg / cm.

In the case where the skin 2 is weak to heat and is deteriorated or deformed, it can be heated from the substrate 1 side as shown in FIG. In this case, a substrate having good thermal conductivity is used as the substrate 1.

Next, various embodiments of the present invention are shown in Table 1.

[0012]

[Table 1]

In Table 1, the thermoplastic resin 3 used in Example 1 is a polyamide-based nonwoven fabric having a basis weight of 20 g / m ² and a melting point of 120 ° C. In Example 2, a polyamide-based powder is used and a basis weight of 30 g. / M ² and a melting point of 80 ° C. Examples 3 to 5
Thermoplastic resin 3 is a polyamide-based powder having a basis weight of 30
g / m ² and a melting point of 120 ° C. The number in parentheses in the base material 1 and the heat insulating material 4 indicates the thickness, and the unit is mm. In Example 5, the melamine foam having a thickness of 20 mm described in the above-mentioned publication was thermally compressed to 3 mm. is there. Further, in the evaluation of the non-adhesive portion in Table 1, ○ indicates good, that is, a state in which the non-adhesive portion does not adhere, and X indicates poor, that is, a state in which the non-adhesive portion adheres. In the durability column, the evaluation of the heat insulating material 4 was as follows: ◎: excellent and good; は: slightly changed in thickness but good; △: extremely unusable; ×: surface with uneven shape. . A of the lamination conditions indicates a case where heating is performed from the skin 2 side, and B indicates a state where heating is performed from the base material 1 side.

As the material of the heat insulating material 4, various materials were tried as shown in Table 2.

[0015]

[Table 2]

The numbers in Table 2 indicate the thickness and the unit mm, respectively. Here, using the method of the lamination condition B in Table 1,
In the evaluation of the heat insulating property, ○ indicates that there was no abnormality even after performing the test twice, Δ indicates that the heat was retained in the second test, and X indicates that the test failed in one test. As for the heat insulating property, it is required that the non-adhesive portion does not adhere. In the evaluation of durability, ○ indicates that the product endured 10 or more times of use, and X indicates that it did not endure 10 or more times of use. As for durability, it is required to withstand repeated use without deterioration and deformation at high temperatures. Regarding the workability, it is required that the material can be cut into a certain size and shape easily with scissors or the like. In addition, if the heat insulating material 4 is thick, the boundary between the bonded portion and the non-bonded portion at the end of the heat insulating material 4 becomes ambiguous, and the accuracy deteriorates.

[0017]

As described above, according to the manufacturing method of the present invention, the heat insulating material can be easily processed according to the shape of the base material and the skin, because the shape processing is easy. Since the portion covered with is shielded from heat, the thermoplastic resin corresponding to the portion not covered with the heat insulating material is heated and melted, and the base material and the skin can be easily and quickly bonded.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a manufacturing method according to the present invention.

FIG. 2 is a plan view showing the arrangement of heat insulating materials as viewed from the line II-II in FIG. 1;

FIG. 3 is a cross-sectional view illustrating a manufacturing method when heating is performed from the base material side.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Skin 3 Thermoplastic resin 4 Insulation material 5 Heat press machine

Continuation of the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B29C 65/00-65/82 B32B 31/00-31/30 B68G 7/00-7/12 B32B 5/00-5 / 32

Claims (1)

(57) [Claims] 1. A step of interposing a thermoplastic resin at least in a portion to be bonded between a substrate and a skin, at least one of which is made of a material having heat conductivity, and heating the material made of a material having heat conductivity. placing a heat insulating material easy urethane foam shape processing and melamine form with blocking the cover heat than points that anniversary at a location between the substrate and the skin to be bonded on a substrate or epidermal side A step of setting a base material, a skin, and a heat insulating material having a thermoplastic resin interposed therebetween in a heat press machine, heating the heat from the heat insulating material side, and pressing the whole, and then taking out and melting the hot press machine Bonding the base material and the skin by cooling and solidifying the thermoplastic resin.