JP5236928B2 - Laminated body and method for producing the same - Google Patents

Description

  The present invention relates to a leather skin material used for a cover of a cushion body, and more particularly relates to a laminate in which a urethane foam sheet used as a skin material for a headrest or the like and leather are laminated and a method for manufacturing the same. It is.

  In recent years, leather products have been used in various parts of the interior of automobiles in response to a sense of luxury. For example, a leather surface material is used as a cover material for seat cushions, seat backs, armrests, headrests, and the like.

  In general, in the manufacture of a cushion body made of urethane foam, a manufacturing method is adopted in which a skin material is set in a foam molding die and a urethane raw material is injected to perform integral foam molding of the skin. At this time, the urethane raw material soaks into the skin material, which not only impairs the appearance of the skin material, but also the soft texture. Therefore, the foamed urethane sheet is laminated between the skin material and the urethane foam with a plastic film. There is an example where is used. And when leather is used as the skin material, a plurality of members laminated with leather and the foamed urethane sheet are sewn to form a skin material conforming to the design shape and set in the foam mold, and the skin integrated foam molding Has been done.

  On the other hand, a laminate in which leather and a urethane foam sheet are laminated and bonded via a non-woven hot melt material has been proposed (see Patent Document 1). Although there is no specific description, the laminated body disclosed here seems to be suitably used as a cover material that covers a cushion body that places importance on air permeability. If this laminate is used as the skin material for integral foam molding of the skin, the surface of the foamed urethane sheet is not laminated with a plastic film, etc., so the urethane material of the cushion body enters the cells of the foamed urethane sheet and is solid. A part will be formed. Therefore, the skin material formed by the laminating technique disclosed herein is not preferable because the soft elasticity unique to the foam is impaired. Further, when a plurality of laminates are sewn to form a bag-like skin for a headrest, for example, if the surface of the urethane foam sheet is not laminated with a film, the urethane raw material may leak from the sewn part, which is not preferable. .

Further, as a material used as an ornament such as a door trim, a thin-film skin material in which only a silver surface layer is removed by removing a leather net-like layer has been proposed (see Patent Document 2). This skin material is used by being affixed to a substrate that is a relatively hard elastic body, and when this structure is used as a skin material for a cushion body made of urethane foam, the leather is in a thin film shape. Even if there is some elasticity, there is a strong possibility that it cannot follow the large deformation of the cushion body, and it is difficult to adopt it as a skin material for the cushion body.
JP 2006-110960 A (refer to [0019] [0020] etc.) Japanese Patent Laid-Open No. 9-39190 (see [0008] etc.)

  As mentioned above, the skin material used when forming the headrest by the skin integral foam molding using urethane raw material is stitched into a bag-shaped skin material by stitching small pieces consisting of multiple laminates, but in the case of using leather Is also sewn in the same way to form a bag-like skin material. As shown in FIG. 4, the laminate is formed by laminating plastic films 12 and 14 on both side surfaces of the urethane foam sheet 13, and leather 40 is laminated on the plastic film 12 side. The plastic films 12 and 14 are bonded to the foamed urethane sheet 13 by frame lamination. A non-adhesive layer is formed between the leather 40 and the plastic film 12 so that the texture of the leather 40 is maintained. And the small piece before sewing of this laminated body is sewed on the outer periphery so that each laminated material is not separated.

  However, the shape of the headrest has a concave curved surface (front surface), and the tension force does not act on the non-adhesive leather, and thus wrinkles and sagging are likely to occur. In addition, since the laminated body before sewing to the bag-shaped skin material needs to be temporarily sewn at the small piece stage, there is a problem that extra man-hours are added to the cost. As an improvement measure, the present applicant prepares a small piece of a laminate in which the leather 40 and the plastic film 12 are bonded to each other, forms a bag-shaped skin material according to the sewing method, and forms a headrest by skin-integrated foam molding. did. Then, as a headrest using a leather skin material, a new problem was found although there was no problem such as sagging.

  The new problem is a problem that a flutter-like concave portion appears on the surface of the headrest, and that fine wrinkles different from the texture of leather are generated on the concave curved surface portion of the headrest. As a result of various examinations by the applicant, it was concluded that these problems seem to be caused by a leather net-like layer. The conclusion is that when the back surface of the leather and the plastic film 12 are bonded, the back surface of the portion where the bumpy concave portion appears is a portion of the leather net-like layer where a large amount of adhesive is attached for some reason. It is that. On the other hand, in the other portions, although the vicinity of the tip of the fluffy protrusion is bonded to the plastic film 12, the elasticity of the fluffy protrusion seems to be maintained because the amount of the adhesive is small. That's it. When such a molded product that has been integrally foamed and molded using a skin material made of a laminate is placed in a natural state, the elastic force of the fluffy protrusions that have been elastically compressed and deformed along the mold surface is reduced. The retained part is lifted up by the elastic force rather than the shape along the mold surface. Then, the portion that is firmly bonded and does not relate to the elastic force does not float up, so that the portion appears on the surface as an irregular recess. In addition, it can be explained that the phenomenon in which wrinkles appear on the concave curved surface occurs for the same reason. That is, when the laminate is removed from the mold and the leather surface is lifted, the lifting direction is perpendicular to the concave curved surface at each portion of the concave surface of the headrest, so the leather surfaces interfere with each other. This is a phenomenon in which deformations due to the interference appear in various places and become wrinkled.

  The present invention has been made paying attention to such a problem, and the object of the present invention is as a skin material for a cushion body in which no concave recesses are formed on the surface and no wrinkles are formed on the concave curved surface. The surface to be used is to provide a leather laminate and a method for producing the same.

  In order to solve the above-mentioned problems, the invention of the laminate according to claim 1 is used for a cover of a cushion body, and in a laminate in which leather and a urethane foam sheet are laminated via an adhesive, The fluffy net-like body of the layer is cut off at the tip side, a resin coating layer is formed on the net-like layer, and the resin coating layer of the leather is bonded to the foamed urethane sheet with an adhesive. It is characterized by that.

  According to a second aspect of the present invention, in the laminate according to the first aspect, the resin of the resin coating layer enters the surface of the fluffy net-like body of leather and the gap between the fluffy net-like bodies. It is characterized by this.

  The invention according to claim 3 is the laminate according to claim 1 or 2, characterized in that the resin coating layer is a solidified acrylic or polyamide adhesive.

  According to a fourth aspect of the present invention, in the laminated body according to any one of the first to third aspects, the cushion body is formed by skin integral foam molding using a urethane raw material, and at least part of the outer shape. It has a concave curved surface.

  The invention according to claim 5 is the laminate according to any one of claims 1 to 4, wherein the cushion body is a cushion body used for a headrest.

  The invention according to claim 6 is the laminate according to any one of claims 1 to 5, wherein the foamed urethane sheet is laminated on either side or both of a plastic film and a nonwoven fabric. It is characterized by being.

  In order to solve the above-mentioned problem, the invention of the method for manufacturing a laminate according to claim 7 is used for a cover of a cushion body, and in the method for manufacturing a laminate in which leather and a foamed urethane sheet are laminated via an adhesive. A step of trimming the fuzzy net-like body of the net-like layer on the back side of the leather, a step of forming a resin-coating layer on the net-like layer, and the urethane foam sheet on the surface of the resin-coating layer. And a step of adhering to the substrate.

According to an eighth aspect of the present invention, in the method for manufacturing a laminate according to the seventh aspect, a leather in which a part of the fluffy net-like body is trimmed is inserted between compression rolls, and the net-like state in a compression-deformed state is inserted. by supplying a resin adhesive layer, the resin-made adhesive is applied to the surface of the reticular layer, and fluff-like reticular the resin coating layer by the gap between the body is filled with the resin adhesive Is formed .

  According to the laminated body of claim 1, the fluffy net-like body on the back surface of the leather is cut and aligned so that the thickness of the leather is uniform. Therefore, it is possible to prevent the appearance of a fluffy concave portion formed on the surface of the cushion body, which is caused by the surface of the fluffy net-like body involved in the adhesion between the leather and the urethane foam sheet.

  In addition, if the resin coating layer is formed of a resin that has entered the surface of the fluffy net-like body of leather and the gap between the fluffy net-like bodies, after removing the skin-integrated foam-molded product from the mold, The surface of the laminate is not lifted by the elastic force of the fuzzy net-like body. Therefore, even if a concave curved surface exists in the external shape of the cushion body, generation of wrinkles can be prevented.

  According to the method for manufacturing a laminated body of claim 7, first, a part of the net-like body on the back surface of the leather is physically removed to make the thickness of the leather uniform. Then, a resin coating layer is formed on the leather mesh body having a uniform thickness by removing a part of the mesh body, and the leather is bonded to the foamed urethane sheet on the surface of the resin coating layer. Thus, a laminate is manufactured. Therefore, it is possible to prevent the uneven pattern appearing on the surface of the skin-integrated foam-molded product due to the uneven height of the fluffy net-like body. In addition, the adhesive used to bond the leather and the urethane foam sheet stays on the surface of the resin coating layer, and the adhesive does not reach the net-like body, resulting in partial adhesion of the adhesive. It is possible to prevent the appearance of a rib-shaped recess.

  Further, when forming the resin coating layer on the net-like body, the leather from which the tip side of the net-like body has been removed is inserted between the compression rolls, and the resin adhesive is supplied to the fluffy net-like body in the compression deformed state. By doing so, it is possible to fill the gaps in the fuzzy net-like body with the adhesive. Then, since the fluffy net-like body is fixed by filling the gap, the elastic force of the net-like body that recovers to the original state after the leather is compressed becomes negligibly small, and the integral foam molding of the skin It is possible to prevent the surface of the molded product from floating after the product is removed from the mold. Accordingly, no wrinkles occur even when the external shape is a concave curved surface.

  ADVANTAGE OF THE INVENTION According to this invention, the surface used as a skin | leather material of the cushion body which does not form a flutter-shaped recessed part in the surface, and a wrinkle is not especially formed in a concave curved surface can provide the laminated body of leather, and its manufacturing method. .

(First embodiment)
Hereinafter, an embodiment of a laminate embodying the present invention will be described with reference to FIGS. In addition, about the same structure as a prior art, the same code | symbol used in the description shall be used.

  The headrest 1 shown in FIG. 1 is a general shape, and the shape of the front surface is a concave curved surface 2. FIG. 2 shows a partial cross section of the leather laminate 20 whose surface used as the cover material of the headrest 1. As shown in FIG. 2, the urethane raw material is foamed by so-called skin-integrated foaming to form a foam 15, and the foam 15 and the laminate 20 are bonded and integrated by the adhesive force of the urethane raw material. The laminate 20 is formed by laminating the plastic films 12 and 14 on both sides of the urethane foam sheet 13 and bonding the plastic film 12 on the surface side of the urethane foam sheet 13 and the leather 10 with an adhesive 11. . In this leather 10, as shown in FIG. 3 (d), the adhesive 36 covers the surface of the innumerable fluffy net-like bodies 31 of the net-like layer 32, and creates gaps between the fluffy net-like bodies 31. The coating layer 38 is formed by filling. Therefore, the fluffy net-like body 31 is fixed and is hardly compressed and deformed by the foaming pressure at the time of foam molding, so that the fluffy net-like body 31 returns to the state before compression deformation after being removed from the mold. Occurrence of wrinkles that sometimes develop is prevented. Further, since the coating layer 38 is formed on the surface of the fuzzy net-like body 31 and the gap between them, the adhesive 11 is attached to the entire net-like layer 32, and the adhesive 11 is partly on the net-like layer 32. As a result, it is possible to prevent the occurrence of flutter-like recesses that appear as a result of adhesion.

(Production method)
Next, an embodiment of a laminate manufacturing method embodying the present invention will be described with reference to FIGS.
FIG. 3A is a schematic cross-sectional view showing the material 30 a of the leather 10 that forms the surface of the laminate 20, and the material 30 a is formed by a net-like layer 32 having a silver surface layer 33 and a fluffy net-like body 31. It is configured. In addition, the fuzzy net-like body 31 in the figure is exaggerated and drawn greatly. An intermediate material 30b shown in FIG. 3 (b) is obtained by removing a part of the material 30a from the tip side of the fluffy net-like body 31 with a skiving device (not shown). In the intermediate material 30b, the height of the fluffy net-like body 31 is aligned, and the thickness of the intermediate material 30b is uniformly adjusted. Next, FIG. 3C shows a process of coating the adhesive on the side of the intermediate material 30b where the fuzzy net-like body 31 is present. The intermediate material 30b is inserted between the pair of compression rolls 34, and the surface of the fluffy net-like body 31 in a compressed state is covered with the adhesive 36 supplied between the small rolls 35 and the compression rolls 34, A gap between the fuzzy net-like bodies 31 is filled to form the coating layer 38. As the adhesive 36, a known acrylic or polyamide adhesive is used, and the surface of the coating layer 38 formed by the adhesive 36 is a smooth flat surface. In the figure, 37 is an adjusting member for adjusting the amount of adhesive supplied to the intermediate member 30b. And the leather 10 shown in FIG.3 (d) was manufactured as mentioned above.

  In the present embodiment, the fluffy net-like body 31 is cut out and the thickness of the material 30a is uniformly adjusted to obtain the intermediate material 30b. However, the height of the fluffy net-like body 31 depends on the location. If they differ greatly, most of the fluffy net 31 will be removed.

  Lamination of the plastic films 12 and 14 on both surfaces of the urethane foam sheet 13 is performed by frame lamination which is a known method, although not shown. And after apply | coating an adhesive agent to the plastic film 12, the laminated body 20 is manufactured by adhere | attaching the coating layer 38 and the plastic film 12 of the leather 10. FIG.

  In many cases, leather tanned leather is used, but in this embodiment, the leather is not limited to cowhide. In addition, plastic films 12 and 14 made of polyurethane or the like are often used as a material for laminating the foamed urethane sheet 13, but non-woven fabrics of various materials such as polypropylene may be used instead of the plastic film. Any material and state can be used as a laminate material as long as it can be laminated to the foamed urethane sheet 13 and the adhesive force of the urethane material can act, and the urethane material does not pass easily. sell.

Here, according to the laminated body of the said embodiment, the following effects can be acquired.
(1) In the above embodiment, the fluffy net-like body 31 is adjusted to a uniform height, and the adhesive 36 covers the surface of the fluffy net-like body 31 and fills the gaps between the fluffy net-like bodies 31. Thus, the coating layer 38 is formed. For this reason, the elastic restoring force, which is part of the physical properties of the fluffy net-like body 31 that is compressed and deformed by the foaming pressure during foam molding and elastically recovers after demolding, disappears. Therefore, when the luff-like net-like body 31 returns to the state before compression deformation after the cushion body foam-molded and molded with the skin is removed, the surface of the cushion body, particularly the surface that is a concave curved surface, Generation | occurrence | production can be prevented and the laminated body used as a cover material of the cushion body in which the texture of leather is maintained can be provided.

  (2) In the above embodiment, since the coating layer 38 is formed on the back surface of the leather 10, when the leather 10 and the plastic film 12 laminated on the front side of the urethane foam sheet 13 are bonded, the adhesive is leather. It adheres uniformly to the entire 10 mesh-like layers 32. Therefore, it is possible to prevent the occurrence of a flap-like recess due to the impregnation of the adhesive. Therefore, it is possible to provide a laminated body that is used as a cover material for a cushion body having a smooth surface without a rib-like recess.

  (3) In the above embodiment, the tip side of the fluffy net-like body 31 of the material 30a is removed by skiving to form the intermediate material 30b having a uniform thickness, and then the coating is performed using the adhesive 36. Layer 38 was formed. Therefore, the compressibility in the thickness direction of the leather 10, in other words, the recovery force from temporary compression deformation is uniform throughout the leather 10. Therefore, when the cushion body by the skin integrated foam molding is molded using the laminate 20 manufactured by the manufacturing method according to the present embodiment, a cushion body having a smooth leather surface without unevenness can be provided.

  (4) In the above embodiment, since the adhesive 36 is supplied to the intermediate material 30b in a compressed state between the pair of compression rolls 34 to form the coating layer 38, the adhesive 36 is applied to the entire net-like layer 32 of the leather 10. Attached. Therefore, the height of the fluffy net-like body 31 at the time of elastic compression deformation, such as when subjected to foaming pressure of urethane, is kept uniform, and the height at which recovery from compression deformation is uniform is also provided. it can.

  (5) In the above embodiment, the laminate 20 is formed by uniform adhesion using the adhesive 11 between the plastic film 12 of the foamed urethane sheet 13 and the coating layer 38 of the leather 10. Therefore, the texture of the leather can be maintained without expressing an unintended uneven pattern on the surface of the laminate 20.

[Example]
Foam obtained by laminating a part of the tip side of the fluffy net-like body 31 of cowhide and forming a coating layer 38 with an acrylic adhesive 36 and polyurethane plastic films 12 and 14 on both sides. A laminate 20 was obtained by bonding the urethane sheet 13 with the urethane adhesive 11. Using the laminate 20, the headrest 1 was formed by urethane skin integral foam molding, and it was visually checked whether or not a surface-like recess was developed. As a result, no appearance of fluffy recesses was observed in any of the 230 headrests 1.

[Comparative example]
According to the same material and manufacturing method, except that a leather that does not perform any treatment on the fluffy net-like body 31 similar to the material 30a shown in FIG. 3A is prepared and used instead of the leather 10 of the above embodiment. The headrest 1 was molded, and the presence or absence of a surface-like concave portion was also visually checked. As a result, it was confirmed that 11 out of 18 headrests 1 had fluttered depressions, so the comparative experiment was stopped.

[Discussion]
Since, in the comparative example, 11 defective products (flapping recesses) did not appear for 230 headrest molded products, 11 out of 18 products were defective products. The effect was clearly demonstrated in the laminate 20 according to the present invention.

(Example of change)
In addition, you may change the said embodiment as follows.
In the embodiment, the surface of the urethane foam sheet 13 is laminated with a polyurethane film. However, the present invention is not limited to the polyurethane film, and other plastic films, for example, a polyethylene or polypropylene film having fine holes perforated may be employed.
In the above-described embodiment, the laminated body used as the headrest cover is taken up. However, the cushioning body is used as a skin material for integral foam molding of other cushion bodies, for example, a seat seat portion, a backrest portion, an armrest, a console lid, and the like. It can also be adopted for a laminate.

The perspective view of the headrest by which the laminated body of embodiment of this invention was used as a skin material. The partial cross section figure of the laminated body of embodiment of this invention. (A)-(d) is a partial cross section figure which shows the process in embodiment of the manufacturing method of this invention typically. The partial cross section figure of the laminated body in a prior art.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Headrest, 2 ... Concave curved surface, 10 ... Leather, 11, 36 ... Adhesive, 12, 14 ... Plastic film, 13 ... Foam urethane sheet, 20 ... Laminated body, 31 ... Fluffy net-like body, 32 ... Net-like Layer, 34 ... compression roll, 38 ... coating layer

Claims (8)

  In the laminated body that is used for the cover of the cushion body and the leather and foamed urethane sheet are laminated via an adhesive, the fuzzy net-like body of the net-like layer on the back side of the leather has its front end side aligned, A laminate comprising a net-like layer having a resin coating layer, and the leather having the resin coating layer adhered to a urethane foam sheet with an adhesive.   The laminate according to claim 1, wherein the resin of the resin coating layer enters a surface of the leather fluffy net-like body and a gap between the fluffy net-like bodies.   The laminate according to claim 1 or 2, wherein the resin coating layer is a solidified acrylic or polyamide adhesive.   The laminated body according to any one of claims 1 to 3, wherein the cushion body is formed by integral foam molding of a urethane raw material and has a concave curved surface at least in a part of the outer shape.   The laminate according to any one of claims 1 to 4, wherein the cushion body is a cushion body used for a headrest.   6. The laminate according to claim 1, wherein both sides of the foamed urethane sheet are laminated with one or both of a plastic film and a nonwoven fabric.   In the method of manufacturing a laminate that is used for the cover of the cushion body and laminates leather and foamed urethane sheet via an adhesive, the step of trimming the fuzzy net-like body of the net-like layer on the back side of the leather, A process for producing a laminate comprising a step of forming a resin coating layer on a net-like layer and a step of adhering leather to the urethane foam sheet on the surface of the resin coating layer. A piece of leather with a part of the fluffy net-like body cut through is inserted between compression rolls, and a resin adhesive is supplied to the compression-deformed net-like layer, and the resin adhesive is applied to the surface of the net-like layer. The method for producing a laminate according to claim 7, wherein the resin coating layer is formed by applying the resin coating and filling a gap between the fluffy net-like bodies with a resin adhesive.

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