JP3502407B2 - Cushion material and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material and a method of manufacturing the same, and more specifically, a cushioning material which is excellent in a soft feeling when sitting (comfortable feeling) and is less likely to have wrinkles on its surface layer, and It relates to a manufacturing method. INDUSTRIAL APPLICABILITY The present invention is widely used for cushions for vehicles such as automobiles and other general cushion furniture.

[0002]

2. Description of the Related Art As a conventional skin material, a skin layer made of cloth or synthetic vinyl, a soft foam layer made of foamed polyurethane foam, and a back member (usually backing cloth) layer are laminated. The integrated one is widely used. The role of the backing cloth is to reduce the frictional resistance of the urethane sheet and to facilitate the sewing work because the urethane sheet has a high frictional resistance. On the other hand, there is known a method of manufacturing a cushion material by adhering a skin material to a cushion substrate (pad) using a hot melt adhesive or a solvent type adhesive (Japanese Patent Laid-Open No. 62-146614). Furthermore, as an improvement method, a skin material is arranged along the mold surface of either one of the upper and lower molds, and a cushion base is arranged on one surface side of the skin material, and at this time, the cushion material and the cushion base are opposed to each other. Reactive hot melt adhesive is applied to one of the surfaces, and then hot air is supplied into this air-permeable mold while pressing them against each other with the above-mentioned molds. A method is known in which hot air is supplied to react with each other and adhere to each other (Japanese Patent Laid-Open No. 3-68391).

[0003]

However, in the method for producing a cushioning material by adhering the above-mentioned skin material to the surface of the cushion substrate, since the backing cloth is used as the back surface layer and these are pressed, the adhesive is used as the backing material. It penetrates between the fibers that form the fabric. In particular, when a reactive hot melt adhesive is used as the adhesive, the penetration (filling) is remarkable. Therefore, the fibers of the backing fabric layer after the adhesive is cured act as "bones" and become a hard layer.
Therefore, this cushion material has a problem that the entire skin layer is hard and finished even if the backing cloth which should give a soft feeling is used. Further, since the elongation of the skin layer itself is lowered, when the skin layer is folded with the skin layer inside, wrinkles and the like occur on the surface, and the appearance is spoiled. The present invention solves the above problems, is excellent in soft feeling, is less likely to wrinkle in the surface layer even when bent with the skin layer inside, and is conformable to the surface shape of the cushion base portion of the skin material. It is an object of the present invention to provide a cushioning material excellent in heat resistance and a method of manufacturing the useful cushioning material easily and without impairing the texture and appearance of the surface of the skin material.

[0004]

A cushion material according to the first aspect of the present invention is a cushion material comprising a cushion base portion and a skin layer adhered and formed on the surface of the cushion base portion via an adhesive layer. The skin layer is a decorative surface layer, a soft polyurethane foam sheet layer that is adhesively arranged below the decorative surface layer, and a thermoplastic resin film layer that is adhesively arranged below the soft polyurethane foam sheet layer. Consisting of at least a surface of the flexible polyurethane foam sheet layer in contact with at least the thermoplastic resin film layer is provided with a large number of recesses, the thermoplastic resin film layer covers the surface except the large number of recesses, Further, it is characterized in that the above-mentioned many recesses are opened.

The method of manufacturing the cushion material according to the fourth aspect of the present invention is as follows.
A skin material is arranged along the mold surface of either one of the upper and lower molds, and a cushion base is arranged on one surface side of the skin material, and the cushion base and the skin material face each other. Apply adhesive to at least one of the surfaces,
Then, in the method for producing a cushioning material in which these are bonded to each other while pressing them with each other, the skin material is bonded to the breathable decorative surface layer and below the decorative surface layer. Continuous foaming type soft polyurethane foam sheet layer, and a thermoplastic resin film layer which is adhesively arranged on the lower side of the soft polyurethane foam sheet layer, and is in contact with at least the thermoplastic resin film layer of the soft polyurethane foam sheet layer. A large number of concave portions are provided on the surface, the thermoplastic resin film layer covers the surface excluding the large number of concave portions, and the large number of concave portions is opened, and at least a skin material of the upper and lower molds. The mold on the arrangement side is a breathable mold, a reactive hot melt adhesive is used as the adhesive, and hot air is introduced into the breathable mold. , The heat air is supplied to the adhesive via the ventable the skin material, and wherein the adhering the above skin material and the cushion base by activating the adhesive.

The "decorative surface layer" constituting the skin layer of the cushion material of the first invention is not limited to a woven fabric or the like having air permeability, and may be a non-air permeable resin skin layer. However, the breathable surface layer is preferable because it can provide comfort such as difficulty in getting stuffy even when sitting for a long time. On the other hand, the "decorative surface layer" constituting the skin material used in the fourth invention is limited to those having "breathability" such as knitted fabric. This is because it is necessary to pass hot air such as water vapor and supply the hot air to the adhesive.

The above-mentioned "skin material" is obtained by laminating a thermoplastic resin film on one surface of a flexible polyurethane foam sheet having at least one surface provided with a large number of recesses, and then at least the thermoplastic resin film. These are pressed and heat-bonded at a temperature 20 ° C or higher (preferably 40 ° C or higher) higher than the softening point of the resin layer constituting the adhesive surface to bond the two and to open the thermoplastic resin film portion in contact with the recess. Then, the other surface of the soft polyurethane foam sheet is heated and melted, and a decorative surface material is attached to the heated and melted surface, whereby the product can be manufactured. The reason why the temperature for pressure heat bonding is 20 ° C. or higher than the softening point is
This is because if it is less than 20 ° C., the fluidity of the thermoplastic resin film is not sufficient when pressure-bonded by heat, and it is difficult to form openings.

Since the "soft polyurethane foam sheet layer" constituting the above-mentioned skin agent or skin layer is made of a foam, the surface of this foam has a concave portion which is exposed unless a special surface treatment is performed. . The concave portion has open cells, and the open cell rate (the ratio of open cells to the whole open cells and closed cells) is usually 50% or more. The higher the open cell ratio, the more excellent the flexibility is, and the more excellent the effect of introducing the hot air into the adhesive, and the more excellent the curing efficiency of the reactive hot melt adhesive is. The term "concave" as used herein means all that have a dent on the surface, that is, in the case of closed cells, the shape that is closed except for the surface, and in the case of open cells, it communicates with other bubbles. It is used to mean that it has a shape.

The "thermoplastic resin film layer" may be a single layer or a multi-layer composed of two or more layers as long as it is made of a thermoplastic resin. Examples of the thermoplastic resin include polyvinyl chloride, polyethylene, polypropylene,
A synthetic resin selected from polyvinylidene chloride, nylon, polyester, ethylene acrylic acid copolymer, a metal salt of ethylene acrylic acid copolymer, and ethylene vinyl acetate copolymer can be used. Further, when this layer is composed of, for example, a double layer structure, the resin layer constituting the adhesive surface of the thermoplastic resin film may be composed of an ethylene-acrylic acid copolymer.
In this case, since the ethylene-acrylic acid copolymer has a low melting point and is easily melted, the adhesiveness is excellent. Furthermore, the first
In the fourth invention, the "opening ratio of the thermoplastic resin film layer" is preferably 20 to 90%. If the opening ratio is less than 20%, the effect of preventing wrinkles and stretchability are not sufficient, and if it exceeds 90%, the slipperiness of the back surface becomes poor, and the workability at the time of sewing the skin material, which is the basic function of the backing cloth, is poor. Is deteriorated, which is not preferable.

Further, the kind of the adhesive used for forming the "adhesive layer" in the first invention is not particularly limited, but one that constitutes a relatively flexible adhesive layer and is cured at a relatively low temperature. Those which can be made to have such properties or which have excellent heat resistance are preferable. From these viewpoints, the adhesive used here is preferably a reactive hot melt adhesive, particularly a moisture-curable urethane adhesive.

On the other hand, the adhesive used in the fourth invention is a "reactive hot melt adhesive". Here, the reactive hot-melt adhesive is a conventional hot-melt adhesive to which reactivity is added, and after the object to be adhered is once adhered by heat melting or heat softening, a polymer reaction or a crosslinking reaction is performed by itself. Then, it cures and increases the adhesive strength. As this reactive hot melt adhesive, for example, one having an active double bond in the hot melt adhesive and curable by ultraviolet rays, electron beams, etc., having an epoxy group and a latent curing agent, and thermosetting Thing, -NCO group or -Si (OR)
Examples thereof include those having _three groups and the like and curable with water, those having a —SH group and a metal oxide catalyst and curable with oxygen, and the like. Of these, wet-curable adhesives, especially urethane-based adhesives, are usually used. Further, the hot air for activating and curing the reactive adhesive is variously selected depending on the kind of the adhesive used, for example, 70 to 100.
It can be steam or hot air at ℃.

[0012]

In the conventional cushioning material, since the backing cloth layer is filled with the adhesive and cured, this layer is very hard and rigid. Therefore, when this skin layer is folded with the decorative surface layer inside, the backing fabric layer is extremely difficult to stretch in the longitudinal direction (in the surface direction of the film layer).
Wrinkles are likely to occur on the surface layer. On the other hand, in the cushioning material of the present invention, since the thermoplastic resin film layer forming the skin material (skin layer) is provided with a large number of openings, even when the skin layer is bent inward, This outermost thermoplastic resin film layer is likely to stretch in the same direction, so that wrinkles are less likely to occur in the surface layer.

Further, in the manufacturing method of the present invention, the thermoplastic resin film layer is provided with an opening, the polyurethane foam sheet layer has an open cell structure, and the surface layer is made of a breathable material such as woven cloth. Therefore, the entire skin layer has a breathable structure. Therefore, by introducing hot air into a predetermined mold, the hot air easily reaches the adhesive, so that even if a reactive hot melt adhesive is used, the curing reaction can be surely performed. Further, if the cushion base body also has a ventilation structure by this ventilation structure, it is possible to manufacture a cushioning material which is very comfortable to sit on.

Further, the reactive adhesive used in the present manufacturing method reacts and hardens by itself upon contact with hot air to firmly bond the two. Therefore, before the reaction with the hot air after the pressing, the adhesive layers before the reaction are present, but the two do not adhere to each other, so that the mutual alignment can be facilitated. Furthermore, for the same reason, even when the cushion base has a deep recess, the skin material can be pushed into the recess by pressing force.
The skin material can be sufficiently adhered to the recessed shape. This excellent followability is further reinforced by the soft skin layer. Therefore, a high-quality cushion material can be manufactured even if a cushion base having a complicated shape and a concave portion is used.

Further, since this reactive adhesive reacts and cures by itself to increase the adhesive strength, it can be bonded at a relatively low temperature and the bonded portion exhibits extremely high heat resistance. Therefore, unlike the conventional method, it is not necessary to use an adhesive having a high softening point and a high melting point in order to secure high heat resistance at the bonded portion, and therefore, the skin material and the cushion base are exposed to high temperatures during manufacturing. There is no. Therefore, both of them are not damaged, and especially the texture of the surface of the skin material is not greatly impaired. Further, according to the present manufacturing method, since the skin material having the thermoplastic resin film layer (for example, polyethylene), which is more slippery than the polyurethane foam sheet layer, as the outer layer is used, the production efficiency can be improved. Further, as the skin material, since the flexible polyurethane foam sheet layer is used as the intermediate layer which occupies a large proportion, it is excellent in heat resistance and conformability to the mating material.

[0016]

EXAMPLES The present invention will be specifically described below with reference to examples. Examples 1 to 3 and Comparative Example 1 In this example, a skin material made of a three-layer composite sheet was manufactured,
The performance of this skin material was evaluated. (1) Fabrication of skin material (composite sheet) First, a thermoplastic resin film is placed on a soft polyurethane foam sheet (foaming ratio: 35 times) 21 having a thickness of 6 mm, a density of 0.030 g / cm ³ and a hardness of 13 kg / 314 cm ^2. (Thickness 25 μm) 22 (Note that the same reference numerals as those of the constituent parts of the skin material shown in FIG. 2 are given for convenience.
Other components other than this film are the same. ) Is piled up. The thermoplastic resin film 22 includes a polyethylene resin film layer (thickness 20 μm) 221 and an ethylene-acrylic acid copolymer layer (thickness 3 μm) 222 coated and formed on the one surface. The ethylene-acrylic acid copolymer layer 222 is arranged inside as an adhesive layer.

After that, a metal restraining roll having the same diameter as the rubber roll having a diameter of 430 mm was separated by 2.0 mm.
And place it above. This roll is previously heated to 150 ° C., which is about 45 ° C. higher than the softening temperature of the thermoplastic resin film (softening point of polyethylene film: about 105 ° C.). Then, the both stacked sheets were passed between the rolls while being heated and compressed at a speed of 5 m / min. Thereby, only the ethylene-acrylic acid copolymer layer is melted, the polyethylene sheet is sufficiently softened, both sheets are adhesively laminated, and the thermoplastic resin film portion in contact with the concave portion 211 provided on the surface of the foamed sheet is opened. Let

Then, it was left to cool and then wound to produce a two-layer laminated sheet. Further, while the surface of the soft polyurethane foam sheet layer 21 of the two-layer laminated sheet was heated and melted by a gas burner, the decorative surface material 23 was attached to the melted surface to obtain a three-layer composite sheet 2A.
The surface cloth 23 is knit (weight: 335 g).
/ M ² ) was used.

As shown in FIG. 2, the three-layer composite sheet 2A has a decorative surface fabric layer 23, a soft polyurethane foam sheet layer 21, a thermoplastic resin film layer (ethylene-acrylic acid copolymer), in order from the front side. Layer 222 and polyethylene resin film layer 221.) 22. Then, the thermoplastic resin film layer 22 is
The surface excluding the large number of concave portions 211 is covered, and a portion corresponding to the large number of concave portions 211 is opened. The thermoplastic resin film portion located on the concave portion 211 is bent toward the inner wall side of the concave portion 211 (a bent portion;
223). The aperture ratio is 18%. The measurement of the aperture ratio is an optically magnified image with light and shade,
It was carried out by a method of integrating the light portion as an opening portion by computer processing.

Example 2 A three-layer composite sheet was produced in the same manner as in Example 1 except as described below. The temperature of the metal pressing roll is 190 ° C., the roll interval is 1.0 mm, and the roll speed is 12 m / min. The opening ratio of the thermoplastic resin film layer should be 65%.

Example 3 A three-layer composite sheet was produced in the same manner as in Example 1 except as described below. As the thermoplastic resin film, a single layer product of a polyethylene resin film (that is, having no ethylene-acrylic acid copolymer layer) was used. The temperature of the metal holding roll is 200 ° C., and the roll interval is 1.0 mm. The opening ratio of the thermoplastic resin film layer is 80%.

COMPARATIVE EXAMPLE 1 Nylon tricot (20 denier) knitted fabric was used in place of the thermoplastic resin film, in the same manner as the decorative skin.
A three-layer composite sheet was produced in the same manner as in Example 1 except that the surface of the soft polyurethane sheet was melted by heating and laminated.

(2) Performance Evaluation of Three-Layered Composite Sheet This performance evaluation (wrinkle prevention effect when folded, stretchability and flammability) was carried out by the following test method. The test results are shown in Table 1.

[0024]

[Table 1]

Reverse R Method (Wrinkle Generation Test When Bent) With a wrinkle test jig 5 having a concave R (FIG. 3), the test piece 2A is placed with the surface cloth layer on top as shown in FIG. set.
The setting is performed in order from the one having a sufficiently large radius to the one having a small radius, and the radius (R) at which creases are generated is recorded on the surface fabric layer. In this case, it is advantageous that the crease does not occur up to a radius as small as possible. This is because the folds and wrinkles of the composite sheet product have a great influence on the dynamic wrinkles after the seat assembly and the tests by the seat manufacturer such as the durability test. Elasticity test In advance, clamp both ends of each three-layer composite sheet with a length of 200 mm and a width of 25 mm with a chuck, and
Read the load at 25% elongation when the tensile test was performed at a crosshead speed of 00 mm / min. The test was performed according to flammability MVSS-302.

(3) Effects of Examples and Comparative Examples The composite sheets according to Examples 2 and 3 in which the opening ratio of the thermoplastic resin film is 65 to 80% are more resistant to wrinkle generation than Comparative Example 1. Not only is it extremely remarkably excellent in stretchability, Further, when the opening ratio of the thermoplastic resin film is 18% (Example 1), the same resistance and stretchability are slightly reduced as compared with Examples 2 and 3, but both performances are compared with Comparative Example 1. Both are remarkably excellent. Therefore, it is possible to easily follow a complicated mating material shape such as a concavo-convex shape, and it is possible to obtain a beautiful appearance and obtain a soft feel.

Examples 4 to 6 and Comparative Example 2 In this example, a cushioning material (seat back) was manufactured using a special three-layer type skin material as shown in the above-mentioned examples. (1) Structure of Cushion Material As shown in FIG. 1, the cushion material 1 manufactured in the present embodiment comprises a cushion base (pad) portion 3 and a skin layer 2. The skin layer 2 is adhered and formed on the surface of the cushion base 1 via an adhesive layer 4. The skin layer 2 includes a decorative surface layer (knit layer) 23, a soft polyurethane foam sheet layer 21 that is adhesively arranged on the lower side of the decorative surface layer 23, and a soft polyurethane foam sheet layer 21 below the soft polyurethane foam sheet layer 21. And a thermoplastic resin film layer 22 that is adhesively disposed on the side. Further, as shown in FIG. 2, a large number of concave portions 211 are formed on the surface in contact with the soft polyurethane foam sheet layer 21 and the thermoplastic resin (polyethylene) film layer 22.
The thermoplastic resin film layer 22 covers the surface excluding the large number of concave portions, and is open on the large number of concave portions.

(2) Production of each skin material and performance evaluation when impregnating the same with each other. First, each skin material shown in Table 2 (Examples 4 to 6 and Comparative Example 2) was prepared as in Example 1 above. It was obtained by the same method as. The soft polyurethane foam sheet used had a thickness of 6 mm,
Density 0.060 g / cm ³ , open cell ratio 98% and hardness 1
The one used was 3 kg / 314 cm ² . As the thermoplastic resin film, the one having the same two-layer structure as that used in Example 1 (total thickness 25 μm) was used, and the temperature of the pressing roll was 200 ° C., 170 ° C., 150 in Examples 4, 5, and 6, respectively. C. and the aperture ratio is 80% as shown in Table 2.
%, 45% and 20%. The surface material is the same as in Example 1 above.
The same one was used. In addition, as Comparative Example 2, instead of the thermoplastic resin film, a stretch ester (50
A skin material was produced in the same manner as in Example 1 except that a denier knitted fabric was used.

Next, each skin material was impregnated with an adhesive and cured by the following method and conditions. Kind of adhesive: A moisture-curable hot melt adhesive (registered trademark: "HIBON 4832", manufactured by Hitachi Chemical Co., Ltd.) containing a polyester isocyanate prepolymer as a main component was used. Impregnation method: The adhesive applied to the surface of the cushion substrate (pad) is set in a mold with the skin material covered, heated and melted, and impregnated into the skin material side. Reaction (curing) method and conditions: The reaction proceeds by moisture in the atmosphere.

Performance evaluation (adhesive impregnation condition, sheet durability, stretchability (25% modulus), hardness, wrinkle prevention property, and flammability) was performed for each skin material having a cured adhesive. went. The stretchability, wrinkle prevention property, and flammability are the same as those described above. Other tests are as follows. The results are shown in Table 2.

Adhesive Impregnation 60% to 70% of the total amount of adhesive is in the state of being impregnated into the backing cloth. The rest impregnates the flexible polyurethane foam sheet layer and the cushion substrate (pat). Durability test of seats Comprehensively evaluate the wrinkles, tears, breakage, etc. of the seat immediately after a twisting motion of 100,000 times with a human-shaped mold, and follow the established standards. Score points. The standard for setting the score is based on the limit sample of the set visual judgment standard. Sheet hardness test A rod-shaped compressor having a spherical tip with a radius of 20 mm
Read the load applied when pushed in by 20%.

(3) Manufacture of cushion material (seat back) A cushion material (seat back) 1 was manufactured in the following manner using each of the above skin materials. A description will be given based on FIGS. 5 and 6. First, as shown in FIG. 5, the same moisture-curable hot melt adhesive as described above is spray-applied in a heating and melting state (120 ° C.) to the surface of the cushion pad 3A,
After that, it is cooled to room temperature to form a thin adhesive layer 4A on the same surface. The coating amount is about 50 to 100 g / m ² . This cushion pad was foam-molded by a known method (density 50 kg / m ³ , hardness 20 kg / 31).
4 cm ² ) and has the cross-sectional shape shown in FIG.

After that, the skin material 2A is placed on the die surface 73 of the lower die 7, and the cushion pad 3A is placed on the upper surface of the die surface 73 to align the two. This lower mold 7
A large number of vent holes 72 are provided on the mold surface side in contact with the skin material,
Further, it is a hollow member having a steam introduction hole 71 on the lower side thereof. Then, the steam is supplied through the steam introduction hole 71. In this case, since the adhesive layer 4A makes the adhesive force latent, the cushion pad 3A and the skin 2A can be freely aligned with each other. In such a state, both of them are put between the upper mold 6 and the lower mold 7 by 0.05 to 0.1 kg.
Press each other with a force of / cm ² .

Then, the steam is introduced into the steam introduction hole 71 of the lower mold 7.
When steam of 0 to 80 ° C is supplied, a large number of vent holes 72
Steam is jetted onto the mold surface 73 via. Since the entire skin material has a ventilation structure, the adhesive layer 4A
Will come into contact with steam. Therefore, the steam activates the adhesive and reveals the adhesive force to bond the cushion pad 3A and the epidermis 2A. In this case, hot air may be supplied instead of steam. The activation treatment of the adhesive is preferably performed within 4 to 5 hours after the application of the adhesive.

After that, the inside of the lower mold 7 is replaced with steam to be a negative pressure, and a suction state is set to cool the bonding portion to solidify the adhesive. After that, the adhesive-bonded article was taken out from both molds 6 and 7, and left in the air in an appropriate state to complete the adhesion to manufacture a cushion material. The cushioning properties of this cushioning material were evaluated by sensory evaluation when several monitors were actually seated, and the results are shown in Table 2. Here, “good” in cushioning property means that the flexure is large and soft,
“Defective” means that there is little deflection and a feeling of bottoming out.

Since this cushion material constitutes the seat back of the seat, it can be assembled in the seat back frame and left as it is. The adhesive absorbs moisture in the air while standing and further promotes a cross-linking reaction by itself.
Demonstrates high adhesive strength in about a time, and heat resistance of the bonded area is 1
Improve to about 20 ℃. In order to solidify the adhesive, cold air may be supplied to the lower mold 7 instead of negative pressure.

(4) Effects of Examples 4 to 6 and Comparative Example 2 In comparison of the skin material after impregnated with an adhesive and cured, unlike Comparative Example 2, in each of Examples 4 to 6, an adhesive was applied to the backing material. Since it is not impregnated, the sheet after adhesive curing is soft. Therefore, the durability of the sheet (that is, less wrinkling and less damage) is excellent. Further, since the adhesive having excellent heat resistance is used, this cushion material has high heat resistance. Further, since the epidermis is not exposed to a high temperature of 100 ° C. or higher in the manufacturing process, the epidermis is not damaged (for example, raised hair is collapsed). Furthermore, in this manufacturing method, since the cushion pad and the skin are pressed against each other before the activation of the adhesive, even if there is a deep recess in the cushion pad, the skin material is pushed into this recess and the bottom part thereof is pressed. It was possible to bond the skin along the bottom of the recess with excellent followability.

Further, the flammability, which is an important required quality when used as a cover for an automobile seat cushion material,
Good results have been obtained. In addition, since the entire skin has breathability, the curing reaction can be easily done with steam, it does not get damp even if you sit for a long time, it is warm in winter and cool in summer, and it does not feel stiff and has an excellent soft feeling. It is very comfortable to sit in.

The present invention is not limited to the specific examples described above, and various modifications may be made within the scope of the present invention depending on the purpose and application. That is,
As the decorative surface material, other than knit, other fabrics,
Synthetic vinyl and natural leather can be used. In addition, when applied in the second invention, it is necessary to have air permeability. The type, thickness, softness (hardness), density, expansion ratio, open cell ratio, etc. of the above-mentioned flexible polyurethane foam sheet are variously selected. Further, the opening ratio is the expansion ratio,
It can be adjusted by the size of the foamed pores (pores) and further by the heating temperature and the like. Further, it is also possible to increase the aperture ratio by using as the thermoplastic resin film positively provided with a large number of holes. The material of the thermoplastic resin film, the presence or absence of lamination, the number of laminations, the thickness, etc. are not particularly limited. For example, as this material, in addition to the polyethylene resin,
Polypropylene, vinyl chloride, polystyrene and the like can be used. Further, as the above-mentioned skin material, a so-called one in which a so-called skin layer and a cover pad are integrated can be used. Furthermore, the cushion pad serving as the cushion base may have other sizes, shapes, materials, etc. depending on the purpose. The pad may be filled with a reinforcing member.

[0040]

In the cushioning material of the present invention, since the skin layer is soft, the surface is less likely to wrinkle, is less damaged, and is comfortable to sit on. According to the present manufacturing method, the useful cushioning material can be manufactured by a simple method of introducing hot air, the positioning of the skin material and the cushion base can be easily performed, and the skin material can follow the surface shape of the cushion base. It is also excellent in heat resistance, does not impair the texture and aesthetics of the surface of the skin material, and can secure adhesion with excellent heat resistance.

[Brief description of drawings]

FIG. 1 is a partial explanatory cross-sectional view of a cushion material manufactured in an example.

FIG. 2 is a partial explanatory cross-sectional view of a skin material according to an example.

FIG. 3 is a perspective view of a wrinkle test jig used in Examples.

FIG. 4 is an explanatory diagram for performing a wrinkle test on a test piece using the jig shown in FIG.

FIG. 5 is an explanatory diagram showing a state in which an adhesive is applied to the cushion pad in the example.

FIG. 6 is an explanatory cross-sectional view showing a state in which a cushion pad and a skin material are pressedly arranged between an upper mold and a lower mold.

[Explanation of symbols]

1; cushion material, 2; skin layer, 2A; skin material (3-layer composite sheet), 21; soft polyurethane foam sheet layer, 2
11; recessed portion, 22; thermoplastic resin film layer, 221;
Polyethylene resin film layer, 222; ethylene-acrylic acid copolymer layer, 223; bent portion, 23; decorative surface fabric layer, 3; cushion base portion, 3A; cushion material (cushion pad), 4; adhesive layer, 4A; Adhesive (layer), 5; Wrinkle test jig, 6; Upper mold, 7; Lower mold,
71; Steam introduction hole, 72; Vent hole, 73; Mold surface.

[Table 2]

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI B32B 5/18 101 B32B 5/18 101 27/06 27/06 // B29K 105: 04 B29K 105: 04 B29L 31:58 B29L 31 : 58 (72) Inventor Mori ▲ High ▼ Kan 25, Kamifujiike, Yoshihara-cho, Toyota-shi, Aichi, Araco Co., Ltd. (72) Inventor, Hideki Koike, 25, Kamifuji-ike, Yoshihara-cho, Aichi, Toyota 56) References JP-A-3-133624 (JP, A) JP-A-3-68391 (JP, A) JP-A-6-126873 (JP, A) Actual development Sho-56-46471 (JP, U) (58) ) Fields surveyed (Int.Cl. ⁷ , DB name) B68G 7/05 A47C 7/18 A47C 31/02 B29C 65/42 B29C 65/44 B32B 5/18 101 B32B 27/06 B29K 105: 04 B29L 31: 58

Claims (6)

(57) [Claims] 1. A cushion material comprising a cushion base portion and a skin layer adhered and formed on the surface of the cushion base portion via an adhesive layer, wherein the skin layer is a decorative surface layer and the decoration. A flexible polyurethane foam sheet layer that is adhesively arranged on the lower side of the surface layer for use,
The flexible polyurethane foam sheet layer comprises a thermoplastic resin film layer which is adhesively arranged on the lower side, and at least a surface of the flexible polyurethane foam sheet layer in contact with the thermoplastic resin film layer is provided with a large number of recesses, A cushion material, characterized in that the thermoplastic resin film layer covers the surface excluding the large number of concave portions, and that the large number of concave portions are opened. 2. The cushion material according to claim 1, wherein the opening ratio of the thermoplastic resin film layer is 20 to 90%. 3. The cushioning material according to claim 1, wherein the adhesive layer is made of a reactive hot melt adhesive. 4. A skin material is arranged along the mold surface of either one of the upper and lower molds, and a cushion base is arranged on one surface side of the skin material, in which case the cushion base and the skin are arranged. In a method for manufacturing a cushioning material, wherein an adhesive is applied to at least one of the facing surfaces of the material, and then these are bonded to each other while pressing them with each other in the mold, the skin material is a breathable material. Decorative surface layer, a continuous foaming type soft polyurethane foam sheet layer which is adhesively arranged on the lower side of the decorative surface layer, and a thermoplastic resin film layer which is adhesively arranged on the lower side of the soft polyurethane foam sheet layer. And a plurality of recesses are provided on the surface of the flexible polyurethane foam sheet layer in contact with at least the thermoplastic resin film layer, and the thermoplastic resin film layer is a surface excluding the plurality of recesses. At least the upper and lower molds are covered, and at least the mold on the side on which the skin material is arranged is a breathable mold. As the adhesive, a reactive hot melt adhesive is used. Used,
Further, while introducing hot air into the breathable mold,
The method for producing a cushion material, wherein the hot air is supplied to the adhesive through the skin-permeable skin material and the adhesive is activated to bond the skin material to the cushion base material. . 5. The method for producing a cushion material according to claim 4, wherein the thermoplastic resin film layer has an aperture ratio of 20 to 90%. 6. The method for producing a cushioning material according to claim 4, wherein the reactive hot melt adhesive is a wet-curable adhesive, and the hot air is steam.