JP5094166B2 - Polyurethane foam laminate and method for producing the same - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a polyurethane foam laminate and a method for producing the same, and is intended to prevent unevenness and wrinkles from being generated on a surface material or the like when a surface material and a back material are melt bonded with a polyurethane foam interposed by a frame laminating method. In particular, it is suitable when a thin surface material is used.

  As one of sheet-like materials used for vehicle seats, sofas, mattresses, vehicle interior materials, etc., there is a polyurethane foam laminate in which a flexible polyurethane foam is interposed between a surface material and a back material.

  As a method for producing this polyurethane foam laminate, there are a method using an adhesive, a method using a hot melt film, a method in which a flexible polyurethane foam is heated and melted by a high frequency welder or a flame, etc. In particular, a so-called frame laminating method, in which a flexible polyurethane foam is melt-bonded by a flame, does not require a drying step and has a wide bonding speed, and is widely adopted.

  However, in this frame laminating method, heat-melting tends to be non-uniform, and when a surface material is pressure-bonded after heat-melting a flexible polyurethane foam, for example, a polyurethane foam having a thickness of 5 mm is heated on the fabric as the surface material. When melted and passed between rolls with a roll gap of about 3.5 mm, the surface material and polyurethane foam are bonded by being slightly crushed, but the polyurethane foam tends to be unevenly restored in the thickness direction. Therefore, irregularities and wrinkles are generated in the surface material after bonding, and it is particularly remarkable when a thin surface material is used.

  Therefore, as a method for suppressing such irregularities and wrinkles generated on the surface material, for example, in the method disclosed in Patent Document 1, a heat shielding material is applied to a polyurethane foam surface in a desired shape, and the portion not applied Is heated and melted to prevent wrinkling of the surface material as partial adhesion.

In addition, although it is not a technique for suppressing the occurrence of irregularities and wrinkles on the surface material, Patent Document 2 discloses that a slab polyurethane foam for frame laminating is made as thin as about 1 mm as a method that can reduce the frame laminating method. It has been proposed to reduce the amount of expensive flame retardant slab polyurethane foam used.
JP 58-92558 A Japanese Utility Model Publication No. 60-166532

  However, in the method of manufacturing a frame laminate sheet described in Patent Document 1, it is necessary to apply a heat shielding material in a desired shape, which increases the number of processes.

  Moreover, in the interior covering material described in Patent Document 2, it is thinned in order to reduce the amount of expensive slab polyurethane foam for frame lamination. Even if it is melted almost uniformly, the thickness variation cannot be absorbed. In particular, when a thin surface material is used, unevenness and wrinkles are noticeable.

  Also, when trying to produce a long laminate, elongation occurs at the time of delivery, or process control when frame laminating is difficult, and if the previous melt thickness increases, the subsequent melt thickness almost disappears and the later There is a problem that poor adhesion of the face material is likely to occur.

  The present invention has been made in view of the above-described problems of the prior art, and provides a polyurethane foam laminate that can be laminated without generating irregularities or wrinkles on a surface material or the like even by a frame lamination method, and a method for producing the same. It is what.

  In order to solve the above-mentioned problems of the prior art, the present inventors have earnestly studied a method for producing a polyurethane foam laminate using a frame laminating method in which a polyurethane foam interposed between a surface material and a back material is heated and melted to adhere the surface material and the back material. As a result of repeated studies, in the normal frame laminating method, the polyurethane foam is heated and melted and the polyurethane foam is left as it is in the middle to ensure cushioning and sound absorption, as well as stretchability and three-dimensionality as a laminate. The polyurethane foam to be interposed is thick and needed to remain as it is even after melt-bonding. To prevent irregularities and wrinkles that occur on the surface material, etc., the polyurethane that heats and melts Influence of foam thickness and polyurethane foam thickness In particular, when the thickness of the polyurethane foam when the other is heated and melted after the other is heated and melted, the occurrence of unevenness and wrinkles on the previously bonded surface material becomes remarkable, and the thickness of the polyurethane foam to be left as it is It has been found that unevenness and wrinkles are likely to occur when the thickness is increased, and the present invention has been completed. The specific configuration is as follows.

That is, the polyurethane foam laminate according to claim 1 of the present invention is a polyurethane foam in which a polyurethane foam is interposed between a surface material and a back material, and the polyurethane foam is heated and melted to bond the surface material and the back material. The laminated body is made of a polyurethane foam having a thickness of 1.5 to 3.0 mm, and either one of the surface material or the back material is first melt bonded to one side of the polyurethane foam, and then wound. Without melting, the other face material is melt bonded to the other surface, and the melt thickness of the polyurethane foam to be bonded later is made larger than the melt thickness of the polyurethane foam to be bonded first, to become the total thickness of the polyurethane foam containing the hot-melt adhesive layer after hot-melt adhesive of the double-sided material as 0.8mm or less It is an butterfly.

According to this polyurethane foam laminate, the polyurethane foam is a polyurethane foam laminate in which a polyurethane foam is interposed between a surface material and a back material, and the polyurethane foam is heated and melted to adhere the surface material and the back material. The thickness of 1.5 to 3.0 mm, and either one of the surface material or the back material is first melt bonded to one side of the polyurethane foam, and then the other side is not wound on the other side. In addition, the melt thickness of the polyurethane foam to be bonded later is made larger than the melt thickness of the polyurethane foam to be bonded first, and the melt adhesion after the melt bonding of the double-sided material is performed. The total thickness of the polyurethane foam including the layer is 0.8 mm or less. And 5～3.0Mm, the previous melt thickness after be reserved melt thickness to ensure more to form a homogeneous melt adhesive layer can be bonded, yet the polyurethane foam containing melt adhesive layer total The thickness is reduced to 0.8 mm or less to suppress the influence of the restoration of the polyurethane foam so that the surface material is not uneven or wrinkled.
In addition, by performing melt bonding of the front and back materials in one pass, the influence of intermediate winding is eliminated, and unevenness and wrinkles are further prevented from occurring on the surface material.

Furthermore, in the polyurethane foam laminate according to claim 2 of the present invention, in addition to the configuration according to claim 1 , any one of the melt thicknesses of the polyurethane foam to be bonded to either the surface material or the back material is selected. The melted thickness of the polyurethane foam to be bonded first is increased and the melted thickness of the polyurethane foam to be melted first is set to 0.6 to 0.8 mm, and then melted to the other side without winding. The melt thickness of the polyurethane foam is set to 0.8 to 1.4 mm, and the total thickness of the polyurethane foam including the melt-bonded layer after melt-bonding the double-sided material is set to 0.8 mm or less. Is.

According to this polyurethane foam laminate, the melt thickness of the polyurethane foam to be bonded to either the front surface material or the back surface material is made larger than the melt thickness of the polyurethane foam to be bonded first, The melted thickness of the polyurethane foam that melts to 0.6 to 0.8 mm is melt-bonded, and the melted thickness of the polyurethane foam that is later melted to the other side without winding is 0.8 to 1.4 mm. In addition, the total thickness of the polyurethane foam including the melt-bonded layer after the melt-bonding of the double-sided material is 0.8 mm or less, and even if the previous melt thickness is secured as 0.6 to 0.8 mm, A melt thickness of 0.8 to 1.4 mm or more is ensured to form a uniform melt adhesion layer so that adhesion can be achieved.

  By suppressing the non-uniform restoration of the polyurethane foam after the uniform melt layer and the melt-bonding, unevenness and wrinkles are not generated on the surface material.

According to a third aspect of the present invention, there is provided a method for producing a polyurethane foam laminate comprising: a polyurethane foam laminate in which a polyurethane foam interposed between a surface material and a back material is heated and melted to bond the surface material and the back material. When manufacturing, the thickness of the polyurethane foam to be interposed is set to 1.5 to 3.0 mm, and the melt thickness of the polyurethane foam to be bonded to either the surface material or the back material is bonded first. The polyurethane foam that is melted and bonded to the other side without being wound up after the melt thickness of the polyurethane foam that is melted first is 0.6 to 0.8 mm and is melted and bonded. The melt adhesive layer after the melt adhesion of the double-sided material is 0.8 to 1.4 mm The total thickness of the polyurethane foam include those characterized in that so as to 0.8mm or less.

According to this method for producing a polyurethane foam laminate, when the polyurethane foam laminate in which the polyurethane foam interposed between the surface material and the back surface material is heated and melted to bond the surface material and the back surface material is produced, the polyurethane foam laminate is interposed. The thickness of the polyurethane foam is 1.5 to 3.0 mm, and the melt thickness of the polyurethane foam to be adhered to either the surface material or the back material is the melt thickness of the polyurethane foam to be adhered first. In addition, the melt thickness of the polyurethane foam to be melted first is 0.6 to 0.8 mm, the melt thickness is 0.6 to 0.8 mm, the melt thickness of the polyurethane foam to be melted later on the other side without being wound is set to 0. A polyurethane film having a thickness of 8 to 1.4 mm and including a melt-adhesive layer after melt-bonding the double-sided material. The total thickness of the foam is set to 0.8 mm or less, the polyurethane foam input thickness is set to 1.5 to 3.0 mm, and the previous melt thickness is set to 0.6 to 0.8 mm. Further, the subsequent melt thickness is set to 0.6 to 0.8 mm, so that a uniform melt layer can be formed and bonded, and the total thickness of the polyurethane foam including the melt bond layer is set to 0. The influence of the restoration of the polyurethane is suppressed by making it as small as 8 mm or less so that unevenness and wrinkles are not generated on the surface material.
In addition, by performing melt bonding of the front and back materials in one pass, the influence of intermediate winding is eliminated, and unevenness and wrinkles are further prevented from occurring on the surface material.

According to the polyurethane foam laminate of claim 1 of the present invention , polyurethane foam is interposed between the surface material and the back surface material, and the polyurethane foam is heated and melted to adhere the surface material and the back surface material. In the laminate, the thickness of the polyurethane foam is 1.5 to 3.0 mm, and either one of the surface material or the back material is first melt bonded to one side of the polyurethane foam, and then it is not wound. The other surface material is melt-bonded to the other surface, and the melt thickness of the polyurethane foam to be bonded later is made larger than the melt thickness of the polyurethane foam to be bonded first, and the double-sided material is Since the total thickness of the polyurethane foam including the melt-bonded layer after the melt-bonding is set to 0.8 mm or less, Was charged thickness over arm and 1.5 to 3.0 mm, it can bond the melt thickness after be reserved ahead of melt thickness to ensure more to form a homogeneous melt adhesive layer, yet melted By reducing the total thickness of the polyurethane foam including the adhesive layer to 0.8 mm or less, the influence of restoration of the polyurethane foam can be suppressed, and unevenness and wrinkles can be prevented from occurring on the surface material.
In addition, by performing melt bonding of the front and back surfaces in one pass, it is possible to eliminate the influence of intermediate winding, and to prevent generation of unevenness and wrinkles on the surface material.

Furthermore, according to the polyurethane foam laminate according to claim 2 of the present invention, the polyurethane foam to which the melt thickness of the polyurethane foam to be adhered after either the front surface material or the back surface material is adhered first. The melted thickness of the polyurethane foam is melted and bonded to the other side without being wound up after the melt thickness of the polyurethane foam to be melted first is 0.6 to 0.8 mm. Is 0.8 to 1.4 mm, and the total thickness of the polyurethane foam including the melt-bonded layer after the melt-bonding of the double-sided materials is 0.8 mm or less, the previous melt thickness is 0.6 to Even if it is secured as 0.8 mm, it is possible to secure a later melt thickness of 0.8 to 1.4 mm or more to form a uniform melt adhesion layer and bond them.

  This suppresses uneven restoration of the polyurethane foam after melt bonding and a uniform melt layer, so that unevenness and wrinkles can be prevented from occurring on the surface material. When it appears. In addition, since there is a thickness of the polyurethane foam and a melt thickness, process management at the time of frame lamination can be facilitated.

According to the method for producing a polyurethane foam laminate according to claim 3 of the present invention, the polyurethane foam laminate in which the polyurethane foam interposed between the surface material and the back material is heated and melted to bond the surface material and the back material. When manufacturing the body, the thickness of the polyurethane foam to be interposed is set to 1.5 to 3.0 mm, and the melt thickness of the polyurethane foam to be bonded to either the front surface material or the back surface material is any one first. More than the melt thickness of the polyurethane foam that adheres to the melt, and after the melt thickness of the polyurethane foam to be melted first is 0.6 to 0.8 mm, the melt is bonded to the other surface without being wound up. The melt thickness of the polyurethane foam is set to 0.8 to 1.4 mm, and the two-sided material is melted after being melt-bonded. Since the total thickness of the polyurethane foam including the adhesive layer was made to be 0.8 mm or less, the thickness of the polyurethane foam was 1.5 to 3.0 mm, and the previous melt thickness was 0.6 to 0.8 mm. As a result, it is possible to secure a further melt thickness of 0.6 to 0.8 mm, thereby forming a uniform melt layer and adhering to the polyurethane foam including the melt adhesive layer. By reducing the thickness to 0.8 mm or less, the influence of polyurethane restoration can be suppressed, and unevenness and wrinkles can be prevented from occurring on the surface material.
Further, by performing melt bonding of the front and back materials in one pass, it is possible to eliminate the influence of intermediate winding, and it is possible to further prevent the surface material from being uneven or wrinkled.

Hereinafter, an embodiment of a method for producing a polyurethane foam laminate according to the present invention will be described in detail.
1 and 2 relate to an embodiment of a method for producing a polyurethane foam laminate of the present invention. FIG. 1 is a schematic configuration diagram of the production process, and FIG. 2 is a cross-sectional view of the polyurethane foam laminate in each step. is there.

  In the polyurethane foam laminate 10 of the present invention, the surface material 11 and the back material 18 are bonded via the polyurethane foam 14 having the melt adhesive layers 14a and 14b having different thicknesses on the front and back surfaces, and the melt adhesive layers 14a and 14b are bonded to each other. The total thickness of the polyurethane foam 14 is 0.8 mm or less.

  And in the manufacturing method of the polyurethane foam laminated body of this invention, the polyurethane foam 14 interposed between the surface material 11 and the back surface material 18 is heat-melted, and the surface material 11 and the back surface material 18 are adhere | attached, polyurethane foam The laminated body 10 is manufactured, and the so-called frame laminating method is used to heat and melt the polyurethane foam 14 and bond it to the surface material 11 and the back surface material 18.

  For example, as shown in FIG. 1, a long surface material 11 is fed from a feed drum 12 and sent between first pressing rolls 13 and 13, as shown in FIG. A long polyurethane foam 14 is fed from the feed drum 15 between the first pressing rolls 13 and 13 and is an inner surface that becomes an adhesive surface with the surface material 11 of the polyurethane foam 14 when reversed by the first pressing roll 13 on the upper side. Is heated and melted by the first burner 16 to form a melt-adhesive layer 14a, which is pressed between the first pressing rolls 13 and 13 with the surface material 11, and the surface material 11 and the polyurethane foam 14 are bonded to each other. The sheets are stacked.

  In this method for producing a polyurethane foam laminate, the polyurethane foam 14 delivered from the delivery drum 15 has a thickness of 1.5 to 3.0 mm, and is melt-bonded to the surface material 11 to be bonded first. Therefore, the polyurethane foam 14 is heated and melted in the same manner as in a normal frame laminating method, for example, with a melt thickness of about 0.5 to 0.9 mm, preferably about 0.6 to 0.8 mm, to obtain a molten adhesive layer 14a. The surface material 11 is first bonded to the molten adhesive layer 14a on one side of the polyurethane foam 14 to form and interpose.

  When the thickness of the polyurethane foam 14 is less than 1.5 mm, it is difficult to produce a long sheet-like polyurethane foam, and the sheet-like polyurethane foam 14 is elongated in the frame laminating process. It becomes difficult to form the molten adhesive layer 14a by heating and melting with a uniform melt thickness.

  On the other hand, when the input thickness of the polyurethane foam 14 exceeds 3.0 mm, the thickness of the melt-bonded layers 14a and 14b that are heated and melted when both surfaces of the polyurethane foam 14 are heated and melted is increased, which is useless. The melted adhesive layers 14a and 14b are formed. Further, if the polyurethane foam 14 is left as it is without being heated and melted, the influence of the restoring force of the polyurethane foam that has passed between the first pressing rolls 13 and 13 becomes large, which causes the surface material 11 and the like to be uneven and wrinkled. .

  Therefore, the input thickness of the polyurethane foam 14 may be 1.5 to 3.0 mm, and preferably 1.8 to 2.7 mm.

  Also, when the melt thickness of the polyurethane foam 14 previously heated and melted is less than 0.5 mm, the melted adhesive layer 14a may be thinned and the adhesive strength may be insufficient, particularly when the heat resistance is inferior. There is.

  On the other hand, even if the melt thickness of the polyurethane foam 14 that is heated and melted is greater than 0.9 mm, it is not possible to expect an improvement in adhesive strength or heat resistance due to the molten adhesive layer 14a. Further, when the other side is sent to the step of bonding, the remaining polyurethane foam is thinned, so that there is a problem that the polyurethane foam is easily stretched.

  Accordingly, the melt thickness of the polyurethane foam 14 heated and melted at the tip of the polyurethane foam 14 may be 0.5 to 0.9 mm, and preferably 0.6 to 0.8 mm.

  After the surface material 11 is melt-bonded to one surface of the polyurethane foam 14 in this way, it is sent between the second pressing rolls 17 and 17 as shown in FIG. When the back material 18 is fed from the feed drum 19 and reversed by the upper second pressing roll 17, the outer side surface that becomes the adhesive surface of the polyurethane foam 14 to the back material 18 is heated and melted by the second burner 20 and melted. An adhesive layer 14b is formed and overlapped and pressed with the back material 18 between the second pressing rolls 17 and 17, and the back material 18 and the polyurethane foam 14 are bonded to each other so that the surface material 11, the polyurethane foam 14 and the back material 18 are bonded. Are stacked and wound on the winding drum 21.

  In this polyurethane foam laminate manufacturing method, when the polyurethane foam 14 is reversed by the upper second pressing roll 17, the polyurethane foam 14 is melt bonded to the back material 18 to be bonded later, so that the polyurethane foam 14 is bonded to the ordinary frame laminating method. In the same manner as described above, for example, the melt thickness is increased from the previous melt thickness, and heating is performed so that the total thickness of the polyurethane foam 14 including the melt-bonded layers 14a and 14b on both sides after the melt-bonding is 0.8 mm or less. After melting, the back surface material 18 is adhered to the melt adhesive layer 14b on the other side of the polyurethane foam 14, and a three-layer laminated state is obtained.

  The melt thickness after the polyurethane foam 14 is heated and melted to be thicker than the melt thickness of the previous polyurethane foam 14 to 0.5 to 0.9 mm, preferably about 0.8 to 1.4 mm, and melted. The total thickness of the polyurethane foam 14 including the melted adhesive layers 14a and 14b on both sides after bonding is 0.8 mm or less, preferably about 0.2 to 0.6 mm, that is, melting without the polyurethane foam 14 being unmelted. From the state of only the adhesive layers 14a and 14b, the polyurethane foam 14 is left as it is slightly.

  By making the subsequent melt thickness of the polyurethane foam 14 greater than the previous melt thickness, the melt adhesive layer 14b can be uniformly melted and a sufficient melt amount necessary for adhesion can be obtained. It is possible to secure the adhesive strength between the back material 18 and the molten adhesive layer 14b.

  That is, if the polyurethane foam 14 that melts first is excessive, thermal expansion occurs in the polyurethane foam 14 at the time of melting, and wrinkles are likely to occur. Even if thermal expansion occurs due to the surface material 11, wrinkles are unlikely to occur. In particular, when the thin surface material 11 is used, generation of wrinkles can be effectively suppressed.

  Furthermore, by setting the total thickness of the polyurethane foam 14 including the melt-bonded layers 14a and 14b on both sides after the melt-bonding to 0.8 mm or less, the portion remaining as the polyurethane foam 14 can be completely eliminated or reduced. It is possible to eliminate the influence of the restoring force due to the polyurethane foam 14 and to prevent the surface material 11 and the back surface material 18 from causing unevenness and wrinkles.

  Further, the melt thickness of the melt adhesive layer 14b after the polyurethane foam 14 is made larger than the melt thickness of the previous melt adhesive layer 14a, and the entire polyurethane foam 14 including the melt adhesive layers 14a and 14b on both sides after the melt adhesion is provided. By setting the thickness to 0.8 mm or less, it becomes easy to set conditions for subsequent heat-melting. For example, the second burner 20 is heated so as to heat and melt most of the polyurethane foam 14 remaining after the previous melt-bonding. Adjust it.

  According to such a method for producing a polyurethane foam laminate, the thickness of the polyurethane foam 14 interposed between the surface material 11 and the back surface material 18 is set to 1.5 to 3.0 mm, and later adhered to the back surface material 18. The melt thickness of the melt-adhesive layer 14b of the polyurethane foam 14 is set to be larger than the melt thickness of the melt-adhesive layer 14a of the polyurethane foam 14 that is first adhered to the surface material 11, and the melt-adhesive layers 14a and 14b after the melt-adhesion are provided. Since the total thickness of the polyurethane foam 14 is made to be 0.8 mm or less, even if the melt thickness of the previous melt adhesive layer 14a is secured, the melt thickness of the subsequent melt adhesive layer 14b is secured more than that. Polyurethane, which can form and bond uniform melt-adhesive layers 14a and 14b, and includes the melt-adhesive layers 14a and 14b. To reduce the total thickness of the Omu 14 it is possible to suppress the effect of the polyurethane foam restored.

  Thereby, by suppressing non-uniform restoration of the uniform melt-adhesive layers 14a, 14b and the polyurethane foam 14 after the melt-adhesion, it is possible to prevent the surface material 11 from being uneven and wrinkled. Therefore, there is also a melt thickness, so that it is easy to manage the process when heating and melting by the frame laminating method.

  Further, according to this method for producing a polyurethane foam laminate, the polyurethane foam 14 is used as a frame laminating foam, and after the surface material 11 is first melt-bonded on one side, the back surface material 18 is not wound on the other side. Since the front and back materials 11 and 18 are melted and bonded in one pass, the influence of intermediate winding can be eliminated, and the surface material 11 does not have unevenness or wrinkles. Can be.

  In addition, as a polyurethane foam used for this polyurethane foam laminated body, the polyurethane foam conventionally used for frame laminating can be used.

  Further, as the surface material, woven fabric, knit, double raschel, moquette, knitted fabric, cowy knit PVC leather, genuine leather or the like is used, and as the back material, knitted fabric, gold width, non-woven fabric, knitted fabric, plain woven fabric or the like is used.

  In the embodiment described above, the surface material that becomes the surface of the product is melt-bonded first, but the back material that becomes the back surface of the product may be melt-bonded first.

  Next, examples of the present invention will be described together with comparative examples. However, the present invention is not limited to these examples.

  In each of the examples and comparative examples, a woven fabric having a basis weight of 200 g / m 2 was used as a surface material, a brushed knitted fabric having a basis weight of 100 g / m 2 was used only in Example 8, and a polyurethane foam for a frame laminate was used. A non-woven fabric was used.

  As a manufacturing method, as shown in FIG. 1, the surface material was first melt-bonded by a frame laminating method, and then reversed and the back material was continuously melt-bonded (except for Comparative Examples 6 and 7).

  And the following each item was evaluated about the polyurethane foam laminated body after adhesion | attachment, respectively. The adhesiveness was evaluated in three stages of ◯, Δ, and X, the surface appearance was evaluated in two stages of ◯ and X, the texture was evaluated in two stages of ◯ and X, and the moldability was evaluated in two stages of ◯ and X. The evaluation results are shown in Table 1 for the examples and Table 2 for the comparative examples, and the contents of the evaluation stage of each evaluation item are as shown in Tables 1 and 2.

Example 1
A woven fabric with a basis weight of 200 g / m2 is used as the surface material, the thickness of the polyurethane foam is 2.5 mm, the melt thickness with the surface material is 0.8 mm, the melt thickness with the back surface material is 1.4 mm, polyurethane foam A polyurethane foam laminate was manufactured with a remaining thickness of 0.3 mm including the molten adhesive layer.
The obtained polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesiveness, surface appearance, texture, and moldability were all good.

(Example 2)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 2.5 mm, the melt thickness with the surface material is 0.7 mm, and the melt thickness with the back material is 1.3 mm. A polyurethane foam laminate was manufactured with a remaining thickness of 0.5 mm including the molten adhesive layer.
The obtained polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesiveness, surface appearance, texture, and moldability were all good.

(Example 3)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 2.2 mm, the melt thickness with the surface material is 0.7 mm, and the melt thickness with the back surface material is 1.3 mm. A polyurethane foam laminate was manufactured with a remaining thickness of 0.2 mm including the molten adhesive layer.
The obtained polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesiveness, surface appearance, texture, and moldability were all good.

Example 4
A woven fabric with a basis weight of 200 g / m2 is used as the surface material, the thickness of the polyurethane foam is 2.7 mm, the melt thickness with the surface material is 0.8 mm, the melt thickness with the back surface material is 1.4 mm, polyurethane foam A polyurethane foam laminate was manufactured with a remaining thickness of 0.5 mm including the molten adhesive layer.
The obtained polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesiveness, surface appearance, texture, and moldability were all good.

(Example 5)
A woven fabric with a basis weight of 200 g / m2 is used as the surface material, the thickness of the polyurethane foam is 2.5 mm, the melt thickness with the surface material is 0.5 mm, the melt thickness with the back surface material is 1.4 mm, polyurethane foam A polyurethane foam laminate was produced with a remaining thickness of 0.6 mm including the molten adhesive layer.
The resulting polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesion strength of the surface material was slightly insufficient in terms of adhesion, but any of the other surface appearance, texture, and moldability Was also ○.

(Example 6)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 1.5 mm, the melt thickness with the surface material is 0.5 mm, the melt thickness with the back surface material is 0.8 mm, polyurethane foam A polyurethane foam laminate was manufactured with a remaining thickness of 0.2 mm including the molten adhesive layer.
The resulting polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesion strength of the surface material was slightly insufficient in terms of adhesion, but any of the other surface appearance, texture, and moldability Was also ○.

(Example 7)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 1.8 mm, the melt thickness with the surface material is 0.6 mm, the melt thickness with the back surface material is 1.0 mm, polyurethane foam A polyurethane foam laminate was manufactured with a remaining thickness of 0.2 mm including the molten adhesive layer.
The obtained polyurethane foam laminate had no irregularities or wrinkles on the surface material, and the adhesiveness, surface appearance, texture, and moldability were all good.

(Example 8)
In contrast to the woven fabric having a basis weight of 200 g / m @ 2 in Examples 1 to 7, a non-raised knitted fabric having a basis weight of 100 g / m @ 2 was used as the surface material, and the input thickness of the polyurethane foam was 2.5 mm. A polyurethane foam laminate was manufactured with a melt thickness of 0.8 mm with the surface material, a melt thickness with the back surface material of 1.4 mm, and a residual thickness including a melt adhesive layer of polyurethane foam of 0.3 mm.
The obtained polyurethane foam laminate had no irregularities or wrinkles on the surface material although the surface material weight was small, and the adhesion, surface appearance, texture, and moldability were all good.

(Comparative Example 1)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 2.5 mm, the melt thickness with the surface material is 1.4 mm, and the melt thickness with the back material is 0.8 mm. A polyurethane foam laminate was manufactured with a residual thickness of 0.3 mm including the melt-bonded layer of polyurethane foam.
The resulting polyurethane foam laminate had an irregularity in the appearance of the surface, which was x.

(Comparative Example 2)
A woven fabric with a basis weight of 200 g / m2 is used as the surface material, the thickness of the polyurethane foam is 2.5 mm, the melt thickness with the surface material is reduced to 0.3 mm, and the melt thickness with the back surface material is 1.2 mm. A polyurethane foam laminate was manufactured with a remaining thickness of the polyurethane foam including the molten adhesive layer of 1.0 mm.
In the obtained polyurethane foam laminate, peeling of the surface material occurred in the adhesiveness, the surface appearance was uneven, and the texture of the polyurethane foam remained stronger than the texture of the surface material in the texture. Was also x.

(Comparative Example 3)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 2.7 mm, the melt thickness with the surface material is 0.7 mm, the melt thickness with the back surface material is 1.0 mm, polyurethane A polyurethane foam laminate was manufactured with a remaining thickness of 1.0 mm including the molten adhesive layer of the foam.
The obtained polyurethane foam laminate had no problem in adhesiveness and was ◯, but the surface appearance, texture and moldability were all x.

(Comparative Example 4)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is increased to 3.2 mm, the melt thickness with the surface material is 0.8 mm, and the melt thickness with the back surface material is 1.7 mm. A polyurethane foam laminate was manufactured with a residual thickness including a melt-bonded layer of polyurethane foam of 0.7 mm.
The obtained polyurethane foam laminate had no problem in adhesion and texture, but the surface appearance was uneven, the moldability was large, the heating amount was large, and both of these evaluations were required. X.

(Comparative Example 5)
A woven fabric with a basis weight of 200 g / m 2 is used as the surface material, the thickness of the polyurethane foam is 2.5 mm, the melt thickness with the surface material is 0.8 mm, and once wound after melt bonding, the melt thickness with the back surface material A polyurethane foam laminate was manufactured with a thickness of 1.4 mm and a remaining thickness including a melt-bonded layer of polyurethane foam of 0.3 mm.
The obtained polyurethane foam laminate had no problem in adhesion and texture, but the surface appearance was uneven, and a roll-up process was required for moldability, making the equipment complicated, and so on. Was also x.

(Comparative Example 6)
A woven fabric having a basis weight of 200 g / m 2 was used as the surface material, and instead of the frame laminating method, the surface material, the polyurethane foam, and the back material were bonded to each other using an adhesive to produce a polyurethane foam laminate.
The obtained polyurethane foam laminate had no problem in adhesion and texture, but the surface appearance was uneven, the application of the adhesive in the moldability was complicated, and a drying step was also required. Was x.

It is a schematic block diagram of the manufacturing process concerning one Embodiment of the manufacturing method of the polyurethane foam laminated body of this invention. It is sectional drawing of the polyurethane foam laminated body in each process concerning one Embodiment of the manufacturing method of the polyurethane foam laminated body of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Polyurethane foam laminated body 11 Surface material 12 Sending drum 13 1st press roll 14 Polyurethane foam 14a Melting | bonding adhesive layer 14b Molten adhesive layer 15 Sending drum 16 1st burner 17 2nd press roll 18 Back material 19 Sending drum 20 2nd burner 21 Winding drum

Claims (3)

A polyurethane foam laminate in which a polyurethane foam is interposed between a surface material and a back material, and the polyurethane foam is heated and melted to adhere the surface material and the back material,
The polyurethane foam has a thickness of 1.5 to 3.0 mm,
After one of the surface material and the back material is first melt bonded to one surface of the polyurethane foam, and the other surface material is melt bonded to the other surface without winding, and after either The melt thickness of the polyurethane foam to be bonded is made larger than the melt thickness of the polyurethane foam to be bonded first, and the total thickness of the polyurethane foam including the melt-bonded layer after melt-bonding the double-sided material is 0.8 mm. A polyurethane foam laminate characterized by comprising: The melt thickness of the polyurethane foam to be bonded to either the front surface material or the back surface material is set to be larger than the melt thickness of the polyurethane foam to be bonded first, and the melt thickness of the polyurethane foam to be melted first. The thickness of the polyurethane foam, which is melt-bonded to 0.6 to 0.8 mm and then melted on the other side without being wound, is 0.8 to 1.4 mm, and the double-sided material is melt-bonded. 2. The polyurethane foam laminate according to claim 1, wherein the total thickness of the polyurethane foam including the subsequent melt adhesive layer is 0.8 mm or less. When manufacturing a polyurethane foam laminate in which the polyurethane foam interposed between the surface material and the back material is heated and melted to adhere the surface material and the back material,
The thickness of the polyurethane foam to be interposed is 1.5 to 3.0 mm,
The melt thickness of the polyurethane foam to be bonded to either the front surface material or the back surface material is set to be larger than the melt thickness of the polyurethane foam to be bonded first, and the melt thickness of the polyurethane foam to be melted first. The thickness of the polyurethane foam, which is melt-bonded to 0.6 to 0.8 mm and then melted on the other side without being wound, is 0.8 to 1.4 mm, and the double-sided material is melt-bonded. A method for producing a polyurethane foam laminate, wherein the total thickness of the polyurethane foam including the subsequent melt-adhesive layer is 0.8 mm or less .

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