JP5398187B2 - Sewing structure of skin material for skin integral foam molding - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a sewing structure of a skin material for skin-integrated foam molding, in which a skin material is sewn three-dimensionally, and a liquid foamable resin is injected into the interior to foam, thereby obtaining a molded body integrated with the skin material. In addition, it is designed to prevent leakage from the liquid foamable resin sewing part and the opening between the edges of the sewing part, especially for molding headrests, armrests and console boxes for vehicles. And suitable.

Headrests for vehicles are one of the products made by the skin-integrated foam molding method, in which the skin material is sewed three-dimensionally and liquid foamable resin is injected into the interior to foam it to obtain a molded body integrated with the skin material. And armrests, console boxes, and the like (see Patent Document 1).
In such a skin integral foam molding method, as shown in FIGS. 4 to 6, for example, as the skin material 2 used when molding a headrest 1, armrest, or console box for a vehicle, viewpoints such as texture and stretchability are used. In general, a material obtained by adhering a flexible polyurethane foam 4 to the back surface of a surface fabric 3 such as woven fabric, non-woven fabric, knitted fabric, or synthetic leather is used. For example, as shown in FIG. After three-dimensional sewing as an intermediate alignment state, as shown in a partially enlarged view in FIG. 6, turn over so that the front fabrics 3, 3 are on the outside, and set the core materials 5, 5 etc. The vehicle headrest 1, armrest, console box, and the like, which are molded bodies integrated with the skin material 2, are placed in a mold and injected with a liquid foamable resin and foamed.

If the liquid foamable resin is injected into the interior where the skin materials 2 and 2 are sewn three-dimensionally, a defect occurs in which the foamable resin leaks outside through the needle hole of the sewing portion 6. Various proposals have been made to prevent leakage of the foamable resin from the holes.
One of them is to prevent the leakage of the foaming resin by sealing the needle hole by covering the sewing part on the back side of the skin material and attaching a polyurethane film after sewing (see Patent Document 2), As shown in FIG. 6, the needle holes are sealed to prevent the leakage of the foaming resin by applying the raising treatment to the back surfaces of the skin materials 2 and 2 and applying the fluffed sealing materials 7 and 7 to sew. (See Patent Document 3). Furthermore, the edges of the skin material are overlapped, and overlock stitching is performed along the overlapped edges to disperse the force applied to the seams and prevent leakage from the needle holes. (See Patent Document 4).

JP-A-4-314507 JP-A-2-55110 JP 2005-34212 A JP-A-8-309765

  However, after sewing according to Patent Document 2, a polyurethane film is adhered to the outside of the needle hole, or the needle material is closed by applying the sealing materials 7 and 7 of Patent Document 3 or sewing. No matter which method is used to prevent the needle hole from being widened by overlock stitching, which is a special sewing method of No. 4, so that the outer fabrics 3, 3 that are sewn before the injection of the foamable resin are outside On the other hand, as shown in an enlarged view in FIG. 6, on the front side of the skin materials 2, 2, the outer fabrics 3, 3 are pulled to both sides around the needle hole portion of the sewing portion 6, while foaming On the back side of the skin materials 2 and 2 into which the resin is injected, the overlapped skin materials 2 and 2 are mouths that spread outwardly between the edges 2a and 2a of the skin materials 2 and 2 around the needle holes of the sewing portion 6. It is easy to be in an open state, and the foamed resin leaks from the opening 8 There is. The leakage of the foamable resin from the mouth opening 8 is particularly noticeable when using synthetic leather having a texture on the skin materials 2 and 2. This is because the surface of the synthetic leather has irregularities, so when the skin materials 2 and 2 are overlapped, a gap is formed, and it is difficult for the skin materials 2 and 2 of the sewing part 6 to be completely adhered to each other. Moreover, since synthetic leather has high airtightness, it is a factor that gas (gas) generated from the foamed resin to be injected tends to concentrate on the sewing portion.

  In addition, for the sewing of a molded body such as the headrest 1, the armrest, the console box or the like, a so-called double stitching method in which a decorative sewing part 21 is provided on both sides of the sewing part 6 is preferably employed from the viewpoint of design. However, in the double stitch, when the decorative sewing portion 21 is sewn, the opening portion 8 tends to be easily generated as compared with a normal sewing method because the sewn portion 6 is strongly pulled to both sides with the sewing portion 6 as a fulcrum.

  The present invention has been made in view of the problems of the prior art, and in addition to preventing leakage of the liquid foamable resin from the needle hole, it is from the opening portion between the edges of the superposed skin material. It is an object of the present invention to provide a sewing structure for a skin material for skin-integrated foam molding that can prevent leakage.

  In order to solve the above-mentioned problems of the prior art, after earnestly examining the sewing structure of the skin material for foam integrated molding, the inner side where the foaming resin is injected, as well as the needle hole by sewing the overlapped portion of the skin material In this case, a mouth opening that causes the outer fabrics to be separated from each other without maintaining the contact state of the outer fabrics between the edges of the two outer skin materials is maintained around the sewn portion, and the foamable resin enters from the opening portion. In order to solve this problem, the present invention has been completed. The specific configuration for solving this problem is as follows.

That is, the sewing structure of the skin material for foam integrated foam molding according to claim 1 of the present invention is a skin integrated foam molding in which a liquid foamable resin is injected into the inside of the molded body and foamed and integrated by sewing. A skin structure for a skin material, wherein the skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam bonded to the inside of the surface fabric, and an edge of the skin material The surface fabrics are overlapped to form an overlap portion, and a nonwoven fabric is provided to cover the outside of the overlap portion, the nonwoven fabric is a melt blown nonwoven fabric, and at least one surface of the nonwoven fabric made of a thermoplastic elastomer resin Or, it is composed of a two-layer or three-layer laminate obtained by thermally bonding a nonwoven fabric made of polybutylene terephthalate or polypropylene on both sides, and has a water pressure resistance of 450 mmH. _{In addition to being 2} O or more, the average pore size is 0.1 to 20 μm, and the overlapped portion is sewn from the outside of the nonwoven fabric to provide a connected sewn portion .

Moreover, the sewing structure of the skin integral foam molding material of Claim 2 of this invention is the structure of Claim 1, and on the both sides which pinch | interpose the said connection sewing part, the edge part of each said nonwoven fabric and each said skin The decorative sewing parts are formed by sewing materials together.
According to the sewing structure of the skin integrated foam molding skin material, on the both sides sandwiching the connection sewing portion, the edge portion of the nonwoven fabric and each skin material are sewn to form a decorative sewing portion, respectively. In addition, even when the decorative sewing portion is formed in order to improve the design, the leakage of the foamable resin from the needle hole of the decorative sewing portion can be prevented by sewing through the nonwoven fabric.

Furthermore, the sewing structure of the skin material for foam integrated foam molding according to claim 3 of the present invention is a skin integrated foam molding in which a liquid foamable resin is injected into the inside of the molded body and foamed and integrated. A skin structure for a skin material, wherein the skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam bonded to the inside of the surface fabric, and an edge of the skin material The surface fabrics are overlapped to form an overlapped portion, and this overlapped portion is sewed to form a connected sewn portion, and the end portions of the respective skin materials are folded back from the connected sewn portion. provided to cover these folded portion and the connecting sewn part is provided a nonwoven, the nonwoven fabric is a meltblown nonwoven fabric, and at least one surface or both surfaces of the nonwoven fabric made of thermoplastic elastomer resin, polybutylene The nonwoven fabric made of terephthalate or polypropylene is composed of a laminate of two or three layers formed by thermal bonding, along with it water pressure resistance 450MmH 2 _O or more, the average pore size is 0.1 to 20 [mu] m, from the outside of the nonwoven fabric Each of the folded portions is sewed to form a decorative sewing portion, and the foamed resin is prevented from leaking from the decorative sewing portion and the connecting sewing portion .

In addition, the sewing structure of the skin material for integral foam molding according to claim 4 of the present invention is a skin integral foam molding in which a liquid foamable resin is injected into the inside of the molded body and foamed to be integrated. A skin structure for a skin material, wherein the skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam bonded to the inside of the surface fabric, and an edge of the skin material At least one of the nonwoven fabrics which are arranged with a space between each other, overlap the nonwoven fabric on the inner polyurethane foam, and are arranged so as to straddle between the edges, and the nonwoven fabric is a melt blown nonwoven fabric and is made of a thermoplastic elastomer resin. It is composed of a two-layer or three-layer laminate formed by heat-bonding a non-woven fabric made of polybutylene terephthalate or polypropylene on one or both sides, and has a water pressure resistance of 450 m. Together are H 2 _O or more, the average pore size is 0.1 to 20 [mu] m, from the edge of the skin material through the non-woven fabric at a predetermined position is formed by sewing decorative sewing portions respectively, decorative stitching unit The surface fabrics of the skin material formed with each other are overlapped with each other to sew the edge side from the decorative sewing portion to form a connected sewing portion, and leakage of the foamable resin from the decorative sewing portion and the connected sewing portion It is characterized by being configured to prevent the above .

According to the sewing structure of the skin material for integral foam molding according to claim 1 of the present invention, the integral skin foam molding in which a liquid foamable resin is injected into the molded body and is foamed and integrated by sewing to the outer shape of the molded body. A skin structure for a skin material, wherein the skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam bonded to the inside of the surface fabric, and an edge of the skin material The surface fabrics are overlapped to form an overlap portion, and a nonwoven fabric is provided to cover the outside of the overlap portion, the nonwoven fabric is a melt blown nonwoven fabric, and at least one surface of the nonwoven fabric made of a thermoplastic elastomer resin or both surfaces, a nonwoven fabric made of polybutylene terephthalate or polypropylene is composed of a laminate of two or three layers formed by thermal bonding, water pressure 450MmH ₂ Taken together with a higher average pore size is 0.1 to 20 [mu] m, the end of this from the outside of the nonwoven fabric by sewing the overlapping portion becomes provided with attachment sewn portion, the coupling sewing portion and the superposed surface material Since it is configured to prevent leakage of the foamable resin from the opening between the edges, the connecting and sewing portion can prevent leakage of the foamable resin from the needle holes by stitching the nonwoven fabrics on top of each other. At the same time, by covering the outer edges of the superposed skin materials with a non-woven fabric, leakage of the foamable resin from the mouth opening can be prevented.
In addition, since a nonwoven fabric having a water pressure resistance of 450 mmH ₂ O or more and an average pore size of 0.1 to 20 μm is used, it is possible to prevent seepage due to penetration of a more liquid foamable resin. Further, leakage of the foamable resin from the mouth opening portion between the end edges can be prevented. In addition, since the average pore size of the nonwoven fabric is 0.1 to 20 μm, it has air permeability through which the gas (gas) generated when the injected foamable resin is foamed appropriately, so that the skin material and the foamable resin Generation of voids at the interface (burrows) can be prevented.
Furthermore, the nonwoven fabric is a melt blown nonwoven fabric, and a two-layer or three-layer laminate formed by thermally bonding a nonwoven fabric made of polybutylene terephthalate or polypropylene to at least one surface or both surfaces of a nonwoven fabric made of a thermoplastic elastomer resin. By configuring it, the required water resistance, air permeability, and pore size can be secured, exudation by permeation of the liquid foamable resin can be prevented, and the gas (gas) at the time of foaming can be appropriately removed. Can be secured. Thereby, leakage of the foamable resin from the opening between the needle hole and the end edge can be prevented. Further, by using a nonwoven fabric made of a thermoplastic elastomer resin, it is possible to give higher flexibility, thereby preventing creases (corners) from easily appearing on the surface of the skin material.
Since the non-woven fabric is composed of a two-layer or three-layer laminate in which a non-woven fabric made of polybutylene terephthalate or polypropylene is provided on at least one side or both sides of a non-woven fabric made of a thermoplastic elastomer resin, it penetrates a liquid foamable resin. It is possible to prevent leakage of foaming resin from the mouth opening between the needle hole and the end edge more reliably, and to sew with a non-woven fabric made of polybutylene terephthalate or polypropylene with low surface friction. The sewing machine is also excellent in feeding performance and can be easily sewn.
Moreover, the adhesive strength with a polyurethane foam can be improved by laminating a nonwoven fabric made of polybutylene terephthalate or polypropylene on one surface of the nonwoven fabric made of a thermoplastic elastomer resin on the polyurethane foam side. In addition, by laminating a non-woven fabric made of polybutylene terephthalate or polypropylene on one side opposite to the polyurethane foam, the slipperiness of the back side of the skin material for skin integrated foam molding is improved, and the sewing work efficiency is improved. I can do it.
As a result, in the molded body obtained by sewing the skin material for foam integrated with the skin, it is possible to prevent leakage of the foaming resin from the opening between the needle hole and the edge of the skin material, and the skin integrated with excellent quality A foam-molded article can be produced.

  According to the sewing structure of the skin material for foam integrated molding according to claim 2 of the present invention, the edge portion of the nonwoven fabric and each skin material are sewn and decorated on both sides of the connection sewing portion. Since each sewn part is formed, even when a decorative sewn part is formed in order to enhance the design, it is possible to prevent leakage of foaming resin from the needle hole of this sewn part by sewing through the nonwoven fabric. be able to.

Furthermore, according to the sewing structure of the skin material for foam integrated foam molding according to claim 3 of the present invention, the skin integrated to be integrated by foaming by injecting a liquid foamable resin into the outer shape of the molded body and injecting the liquid foamable resin inside A sewing structure for a foam molding skin material, wherein the skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam adhered to the inside of the surface fabric, The surface fabrics of the edge are overlapped to form an overlapped portion, and a stitched portion is formed by sewing at the overlapped portion, and the edge portion of each skin material is folded back from the connected stitched portion. the part provided to cover these folded portion and the connecting sewn part is provided a nonwoven, the nonwoven fabric is a meltblown nonwoven fabric, and at least one surface or both surfaces of the nonwoven fabric made of thermoplastic elastomer resin, poly The nonwoven fabric made of Chi terephthalate or polypropylene is composed of a laminate of two or three layers formed by thermal bonding, along with it water pressure resistance 450MmH 2 _O or more, the average pore size is 0.1 to 20 [mu] m, outside the non-woven fabric Since each of the folded portions is sewed to form a decorative sewing portion, and configured to prevent leakage of the foamable resin from the decorative sewing portion and the connecting sewing portion, the connection of the skin material is connected to the connecting sewing. By connecting the sewn parts and the folded parts on both sides with a nonwoven fabric and sewing the folded parts to form decorative sewing parts, these decorative sewing parts are sewed with a nonwoven fabric applied to the needles. Leakage of the expandable resin from the holes can be prevented, and the connected sewn portion can be prevented from leaking out by covering the outside with a nonwoven fabric.
In addition, since a nonwoven fabric having a water pressure resistance of 450 mmH ₂ O or more and an average pore size of 0.1 to 20 μm is used, it is possible to prevent seepage due to penetration of a more liquid foamable resin. Further, leakage of the foamable resin from the mouth opening portion between the end edges can be prevented. In addition, since the average pore size of the nonwoven fabric is 0.1 to 20 μm, it has air permeability through which the gas (gas) generated when the injected foamable resin is foamed appropriately, so that the skin material and the foamable resin Generation of voids at the interface (burrows) can be prevented.
Furthermore, the nonwoven fabric is a melt blown nonwoven fabric, and it is composed of a single layer of a nonwoven fabric made of a thermoplastic elastomer resin or a plurality of layers in which a nonwoven fabric made of another resin is laminated to provide the necessary water resistance, air permeability, and pore size. It is possible to ensure that the liquid foamable resin can be prevented from oozing out and the gas (gas) at the time of foaming to escape properly can be ensured. Thereby, leakage of the foamable resin from the opening between the needle hole and the end edge can be prevented. Further, by using a nonwoven fabric made of a thermoplastic elastomer resin, it is possible to give higher flexibility, thereby preventing creases (corners) from easily appearing on the surface of the skin material.
Since the non-woven fabric is composed of a two-layer or three-layer laminate in which a non-woven fabric made of polybutylene terephthalate or polypropylene is provided on at least one side or both sides of a non-woven fabric made of a thermoplastic elastomer resin, it penetrates a liquid foamable resin. It is possible to prevent the foaming resin from leaking from the mouth opening between the needle hole and the end edge more reliably, and to prevent the leakage by the polybutylene terephthalate resin with low surface friction. The sewing machine has excellent feedability and can be sewn easily.
Moreover, the adhesive strength with a polyurethane foam can be improved by laminating a nonwoven fabric made of polybutylene terephthalate or polypropylene on one surface of the nonwoven fabric made of a thermoplastic elastomer resin on the polyurethane foam side. In addition, by laminating a non-woven fabric made of polybutylene terephthalate or polypropylene on one side opposite to the polyurethane foam, the slipperiness of the back side of the skin material for skin integrated foam molding is improved, and the sewing work efficiency is improved. I can do it.

According to the sewing structure of the skin material for integral foam molding according to claim 4 of the present invention, the skin integral that is sewn into the outer shape of the molded body and injects a liquid foamable resin into the interior for foaming and integration. A sewing structure for a foam molding skin material, wherein the skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam adhered to the inside of the surface fabric, The end edges are arranged at intervals, the non-woven fabric is laminated on the inside polyurethane foam, and is arranged so as to straddle between the end edges. The non-woven fabric is a melt blown non-woven fabric and is made of a thermoplastic elastomer resin. It is composed of a laminate of two or three layers formed by thermally bonding a nonwoven fabric made of polybutylene terephthalate or polypropylene on at least one surface or both surfaces, and has a water pressure resistance of 4 With 0mmH at 2 _O or more, the average pore size is 0.1 to 20 [mu] m, from the edge of the skin material through the non-woven fabric at a predetermined position is formed by sewing decorative sewing portions respectively, decorative stitching unit The surface fabrics of the skin material formed with each other are overlapped with each other to sew the edge side from the decorative sewing portion to form a connected sewing portion, and leakage of the foamable resin from the decorative sewing portion and the connected sewing portion Since the non-woven fabric is applied to the outside and sewn from above, even if the decorative stitched portion sewn with a sewing machine or the like is formed, the needle hole is closed with fine fibers of the non-woven fabric. As a result, it is possible to prevent leakage of the foaming resin injected from the decorative sewing portion.
In addition, even when a mouth opening portion is formed between the edges of the two skin materials, the outer edges of the two skin materials that are outside the mouth opening portion are covered with a nonwoven fabric. The foamable resin can be prevented from entering, and the foamable resin can be prevented from leaking beyond the connected sewn portion.
In addition, the nonwoven fabric is a melt blown nonwoven fabric, and a single layer of a nonwoven fabric made of a thermoplastic elastomer resin or a plurality of layers obtained by laminating a nonwoven fabric made of another resin on the nonwoven fabric allows the liquid foamed resin to penetrate. Water resistance, air permeability, pore size, and the like necessary for preventing water can be secured, and leakage of the foamable resin from the opening portion between the needle hole and the end edge can be prevented.
Furthermore, the non-woven fabric is composed of a two-layer or three-layer laminate in which a non-woven fabric made of polybutylene terephthalate resin is provided on at least one side or both sides of a non-woven fabric made of a thermoplastic elastomer resin, and is a liquid foamable resin More reliably prevent seepage due to penetration of the foam and prevent leakage of the foamable resin from the opening between the needle hole and the edge, while sewing with a non-woven fabric made of polybutylene terephthalate or polypropylene with low surface friction The sewing machine has excellent feedability and can be sewn easily.
In addition, the nonwoven fabric has a water pressure resistance of 450 mmH ₂ O or more, and by using a nonwoven fabric having an average pore size of 0.1 to 20 μm, leakage of the foamable resin from the opening portion between the needle hole and the edge is prevented. Can do.
As a result, the design of the foam integrated foam molding can be enhanced at the decorative sewing part, and there is no need for post-processing to remove the foaming resin leaked from the stitched part of the decorative sewing part or the connected sewing part after molding. Therefore, it is possible to increase the molding efficiency and to produce efficiently.

  As described above, according to the sewing structure of the skin integral foam molding material of the present invention, in addition to preventing leakage of the liquid foamable resin from the needle hole, the opening between the edges of the superimposed skin material Leakage from the part can be reliably prevented. In the sewing structure of the skin material for integral foam molding of this invention, even if it is a form in which a mouth opening such as a double stitch is likely to occur when using synthetic leather having a texture on the skin material, It is possible to reliably prevent leakage of the foamable resin from the opening portion.

Hereinafter, an embodiment of a sewing structure of a skin material for foam integrated foam molding according to the present invention will be described in detail.
FIG. 1 shows an embodiment of a sewing structure of a skin material for foam integrated foam molding according to the present invention. FIG. 1 (a) is a partially enlarged sectional view of a sewing portion shown in a state where a foamable resin is injected, and FIG. It is the elements on larger scale shown in the sewing start state.

  The skin structure 10 of the skin integrated foam molding of the present invention is applied to the sewing portion 6 of the skin material 2, 2 of the headrest 1 for a vehicle, for example, which has already been described with reference to FIG. Yes, the skin material 2 cut into a shape corresponding to the outer shape of the headrest 1 is sewn three-dimensionally and then set in a mold, and insert parts such as reinforcing materials and support pillars are installed therein, and these inserted inserts When a liquid foamable resin is injected into the internal space between the part and the skin material 2 to form a headrest, which is a product of a skin-integrated foamed molded body in which the skin material 2 and the foamed foamed resin are integrated. In addition to leakage of the foamable resin from the needle hole of the sewing part 6, the leakage of the foamable resin from the opening 8 between the edges 2a, 2a of the skin materials 2, 2 can be prevented. is there.

Examples of the skin material 2 used for the sewing structure 10 of the skin integral foam molding skin material include a material formed by bonding a surface fabric 3 and a flexible polyurethane foam 4 as shown in FIG. Can do.
As the front fabric 3 , in addition to the texture, feel and breathability of the headrest 1, fabrics and non-woven fabrics knitted with fibers are used, and conventionally used materials such as natural leather and synthetic leather are used. Used.

Further, the flexible polyurethane foam 4 is adhered to the rear surface side of the table cloth 3, which as such texture and stretchability of the table cloth 3 is not impaired by the foaming resin is injected foam inside is integral It is. As the flexible polyurethane foam 4 , those generally used for skin integral foam molding can be used, but the density is preferably 18 to 60 kg / m ³ , more preferably 35 to 55 kg / m ³ , and the hardness is 90 ~ 500N, more preferably 350 ~ 450N. Moreover, although the thickness changes also with the kind and material of a molded article, it is set to about 1 mm-15 mm, for example.
The back surface of the flexible polyurethane foam 4 may be provided with a synthetic resin film, a non-woven fabric having water resistance or the like in order to prevent the liquid foamable resin to be injected from impregnating the flexible polyurethane foam 4.

In the sewing structure 10 (hereinafter simply referred to as the sewing structure 10) of the skin integral foam molding skin material using the skin material 2 as described above, as shown in FIG. The fabrics 3 and 3 are overlapped with each other in an intermediate state, and the overlapping portion 11 is formed with the edges 2a and 2a of the skin materials 2 and 2 being aligned, and the nonwoven fabric 12 is formed so as to cover the outside of the overlapping portion 11 Is provided.
That is, the nonwoven fabric 12 is arranged so as to continuously cover the flexible polyurethane foams 4 and 4 which are outside the superposed skin materials 2 and 2 and the outside of the edges 2a and 2a between them.
Then, two superposed skin materials 2 and 2 are passed through from the outside of the nonwoven fabric 12 and sewed with a sewing machine or the like to form a connected sewing portion 13, and by the connected sewing portion 13, the two skin materials 2 and 2 are formed. Will be in the connected state.
In this state, since the outer fabrics 3 and 3 of the outer skin materials 2 and 2 are in an inverted state, they are turned over so that the outer fabrics 3 and 3 are on the outer side, as shown in FIG. The connected sewing portion 13 is in a state where it enters the space into which the foamable resin is injected.
Liquid foamable resin is injected into the inside of the skin materials 2, 2 thus sewn three-dimensionally and integrated with the skin material by foaming.

According to such a sewing structure 10, the joint sewing portion 13 sewed with a sewing machine or the like has the non-woven fabric 12 applied to the outside and is sewn from above, so that the needle hole is closed by the fine fibers of the non-woven fabric 12. As a result, the foamed resin to be injected is prevented from leaking.
Furthermore, in this sewing structure 10, when the skin materials 2, 2 are turned over so that the surface fabrics 3, 3 are on the outside with the connecting sewing portion 13 as the center, as shown in FIG. The edges 2a and 2a of the two outer skins 2a and 2a are easily opened to the outside with the connecting sewing portion 13 as a fulcrum due to the elastic force of the flexible polyurethane foams 4 and 4, and the edges 2a and 2a of the two skin materials 2 and 2 Even when the mouth opening 8 where the outer fabrics 3, 3 are separated from each other is formed, the non-woven fabric 12 covers the edges 2a, 2a of the two skin materials 2, 2 outside the mouth opening 8. Therefore, it is possible to prevent the foamable resin from entering, and it is possible to prevent the foamable resin from leaking beyond the connected sewing portion 13.
This eliminates the need for post-processing to remove the foaming resin leaked from the stitched portion after the headrest 1 which is the skin-integrated foamed molded body is formed, and the nonwoven fabric 12 is arranged at the same time as the sewing of the connecting sewing portion 13. Therefore, it is possible to efficiently sew and prevent leakage of the foamable resin.

The nonwoven fabric 12 used in such a sewing structure 10 has a liquid foamable resin permeating into the sewing portion 6 of the skin materials 2 and 2 and the mouth opening portion 8 between the edges 2a and 2a of the skin materials 2 and 2. Further, it is necessary to have heat resistance that does not cause thermal deformation due to contact with the foamable resin.
As the nonwoven fabric 12 having such penetration preventing property and heat resistance, water pressure is used as a physical property representing permeability, and the water pressure (JIS-L1092) is 450 mmH ₂ O (mmAq) or more, preferably 500 mmH. ₂ O or more, more preferably 550 mmH ₂ O or more.
When the water pressure resistance of the nonwoven fabric 12 is less than 450 mmH ₂ O (mmAq), the liquid foamable resin penetrates and exudes.
Airtight backing such as synthetic resin film on the back of the flexible polyurethane foam 4 when the synthetic leather is used for the skin material 2 or to prevent the liquid foamable resin to be injected from seeping into the flexible polyurethane foam 4 Since the airtightness of the skin material is increased, the pressure applied to the sewing portion 6 is increased, and the foamable resin is likely to leak from the sewing portion 6. However, if the nonwoven fabric 12 has water resistance, foaming is possible. It is possible to prevent resin leakage.

Further, when the airtightness of the skin material 2 is increased as described above, the gas (gas) generated during foaming remains without being removed, and when cooled, the skin material shrinks and a cavity called a burrow is generated, whereby the skin material 2 is formed. There is a problem that causes wrinkles. Therefore, it is preferable that the nonwoven fabric 12 has an air permeability (JIS-L1096) of about 0.1 to 20 cc / cm ² . When the air permeability is about 0.1 to 20 cc / cm ² , the gas (gas) generated from the foamable resin escapes from the nonwoven fabric 12 and can prevent the formation of burrows.

Furthermore, the pore size is used as a physical property for determining the water pressure resistance and the air permeability, and the water pressure and air permeability are determined to some extent by the pore size, so the average pore size (measured based on the valve point method of ASTM F-361-80) is 0. It is 1-20 micrometers, Preferably, it is 5-15 micrometers.
When the average pore size of the nonwoven fabric 12 is larger than 20 μm, the water pressure resistance and the air permeability cannot be maintained in the above ranges. The pore size may be any of these values when used as the skin material 2, and when the nonwoven fabric is processed in a subsequent process such as embossing or calendering, the pore size can be adjusted by these processing, After the adjustment, it is sufficient if the above value can be secured in a state before filling with the liquid foamable resin.

Moreover, as the nonwoven fabric 12, it is preferable that the average fiber diameter is 0.1-10 micrometers, More preferably, it is 2-5 micrometers. The fiber diameter is one of the factors that determine the pore size of the nonwoven fabric 12. When the average fiber diameter is increased beyond 10 μm, the pore size increases and it becomes difficult to make the pore size within the above range.
Further, the productivity of the nonwoven fabric having an average fiber diameter of less than 0.1 μm is extremely lowered.
Even if the fiber diameter of the nonwoven fabric 13 is large, the pore size can be set within the above range by post-processing such as embossing and calendering.

Furthermore, it is preferable that the fabric weight of the nonwoven fabric 12 is 30-70 g / m < ² >.
When the basis weight of the nonwoven fabric 12 is less than 30 g / m ^2, it is difficult to obtain the physical properties necessary for the nonwoven fabric, and when it exceeds 70 g / m ² , the fabric becomes hard and tends to be defective.
The preferred basis weight of the nonwoven fabric 12 varies depending on the product as the skin-integrated foamed molded article. For example, in the case of a headrest, a range of 30 to 50 g / m ² is preferable, and in the case of an armrest, 40 to 70 g. A range of / m ² is preferred.
In addition, even if the fabric weight of the nonwoven fabric 12 is the same, the physical properties differ depending on the fiber diameter and the like.

In addition, the manufacturing method of the nonwoven fabric 12 is although it does not specifically limit, The melt blow manufacturing method is preferable. For example, when a general spunbond method, a spunlace method, or the like is used as a method for producing the nonwoven fabric 12, it is difficult to sample a thin fiber diameter in terms of the production method. Therefore, when it is going to obtain the nonwoven fabric 12 of the required water pressure resistance and pore size, it tends to be high in weight and high in rigidity.
On the other hand, according to the melt blow manufacturing method, when spinning a molten resin, it is sprayed and opened with high-speed and high-temperature air and accumulated on a belt or a wire mesh to form a nonwoven fabric. This makes it possible to obtain the nonwoven fabric 12 with appropriate water pressure resistance and pore size in a flexible state with a low weight per unit area.

  The synthetic resin constituting the nonwoven fabric 12 is not particularly limited. However, since the nonwoven fabric is flexible, folds (corners) are less likely to appear on the surface of the skin material, which is preferable in appearance. For example, a thermoplastic elastomer is used. Of these, styrene-based thermoplastic elastomers are more preferable. For example, SEPS (styrene ethylene propylene styrene block copolymer), SIS (styrene isoprene styrene block copolymer), SBPS (styrene butylene propylene styrene block copolymer), SEBS. (Styrene ethylene butylene styrene block copolymer) and the like, and a synthetic resin having water resistance and pore size within the above range can be used.

Moreover, it is preferable that the nonwoven fabric 12 has little frictional resistance. Since the back surface of the nonwoven fabric 12 is made of a resin having a low frictional resistance, the slipperiness during sewing with the sewing machine is improved, and the working efficiency can be improved. Not particularly limited as low resin frictional resistance to be used on the back of this for nonwoven 12, but can be exemplified polyethylene terephthalate phthalate, polyester resins such as polybutylene terephthalate, polyolefin resins such as polypropylene, and polyamide resin, among them, those non-woven fabric is easier meltblown process, polybutylene phthalate, poly propylene.

  Further, as the nonwoven fabric 12, in addition to using the above-mentioned resin in a single layer, other synthetic resins may be laminated to form a nonwoven fabric, which satisfies the physical properties of the nonwoven fabric in the laminated state already described. I just need it.

Next, another embodiment of the present invention will be described with reference to FIG.
FIG. 2 shows another embodiment of the sewing structure of the skin material for foam integrated molding according to the present invention. FIG. 2 (a) is a partially enlarged cross-sectional view of a sewing portion in a state where a foamable resin is injected. Is a partial enlarged view showing the sewing state of the connected sewing portion, (c) is a partial enlarged view showing the sewing state of the decorative sewing portion.

In this sewing structure 20, for example, in addition to connecting the two skin materials 2, 2 at the connecting sewing portion 13 of the sewing portion 6, a decorative sewing portion 21 is provided on both sides of the connecting sewing portion 13 to form a double stitch. Further, leakage of the foamable resin from these decorative sewing parts 21 and 21 can be prevented.
In this sewing structure 20, as shown in FIG. 2 (c), for example, the edges 2a and 2a of the two skin materials 2 and 2 to be sewn are arranged with an interval between them, and the flexible polyurethane foam 4, which is the back surface, 4, the non-woven fabric 12 is overlaid and the non-woven fabric 12 is disposed so as to straddle between the edges 2a, 2a. And in the position which exposes a predetermined double stitch from the edge 2a of each skin material 2, it penetrates through the nonwoven fabric 12 with a sewing machine etc. and sews, and the decorative sewing parts 21 and 21 are formed, respectively.
As a result, the decorative sewing portions 21 and 21 are sewn with the non-woven fabric 12 overlapped, so that the needle holes are closed by the non-woven fabric and leakage of the foamable resin is prevented.
Next, by forming the overlapping portion 11 so that the outer fabric materials 3, 3 are overlapped with the outer skin materials 2, 2 on which the decorative sewing portions 21, 21 are formed, the edges 2 a, 2 a of the outer skin materials 2, 2 are formed. The outer side is covered with the nonwoven fabric 12, and then, as shown in FIG. 2 (b), the skin material 2 sandwiched between the nonwoven fabric 12 at a predetermined position on the edge 2 a, 2 a side from the decorative sewing portions 21, 21. , 2 are sewn with a sewing machine or the like to form a connected sewn portion 13.
As a result, the two skin materials 2 and 2 are connected by the connecting and sewing portion 13 and the decorative sewing portions 21 and 21 are formed on both sides thereof.
In this state, since the surface fabrics 3, 3 of the skin materials 2, 2 are in an inverted state, the inside is turned over so that the surface fabrics 3, 3 are on the outside, as shown in FIG. The connected sewing portion 13 is positioned inside the space for injecting the foamable resin.
Liquid foamable resin is injected into the inside of the skin materials 2, 2 thus sewn three-dimensionally and integrated with the skin material by foaming.

According to such a sewing structure 20, even if the decorative sewing portion 21 sewed with a sewing machine or the like is formed, the non-woven fabric 12 is applied to the outer side and sewn from above, so that the needle holes are finely formed of the non-woven fabric 12. This prevents the foamed resin injected from the decorative sewing parts 21 and 21 from leaking out.
Further, in this sewing structure 20 as well, the connected sewing portion 13 sewed by a sewing machine or the like has a non-woven fabric 12 applied to the outside thereof and is sewn from above, similarly to the above-described sewing structure 10. Is blocked by the fine fibers of the nonwoven fabric 12 and leakage of the foamed resin to be injected is prevented, and the outer fabrics 3, 3 are disposed between the edges 2a, 2a of the two outer skin materials 2, 2. Even when the mouth opening 8 is formed, the edge 2a, 2a of the two skin materials 2, 2 outside the mouth opening 8 is covered with the nonwoven fabric 12, so that the foamable resin is Intrusion can be prevented, and leakage of the foamable resin beyond the connected sewn portion 13 can be prevented.
As a result, the design of the headrest 1 which is a skin-integrated foam-molded body can be enhanced by the decorative sewing parts 21 and 21 and leaked from the stitched parts of the decorative sewing parts 21 and 21 and the connected sewing part 13 after molding. There is no need for post-treatment to remove the foamable resin, and the molding efficiency can be increased and production can be performed efficiently.

  The nonwoven fabric 12 used for such a sewing structure 20 may have the same physical properties as the nonwoven fabric 12 used for the sewing structure 10 already described.

Next, still another embodiment of the present invention will be described with reference to FIG.
FIG. 3 shows still another embodiment of the sewing structure of the skin integral foam molding skin material of the present invention, (a) is a partially enlarged cross-sectional view of a sewing portion in a state where a foamable resin is injected, (b) ) Is a partially enlarged view showing the sewing state of the decorative sewing portion, and (c) is a partially enlarged view showing the sewing state of the connected sewing portion.

In this sewing structure 30, as in the case of the sewing structure 20, for example, in addition to connecting the two skin materials 2 and 2 at the connecting sewing portion 13 of the sewing portion 6, decorative sewing by double stitching on both sides of the connecting sewing portion 13 is performed. In the case where the portion 21 is provided, leakage of the foamable resin from the decorative sewing portions 21 and 21 can be prevented, but this sewing process is different.
In this sewing structure 30, as shown in FIG. 3 (c), for example, the surface fabrics 3, 3 of the two skin materials 2, 2 to be sewn are brought into a centering state and the edges 2a, 2a are aligned. In this state, the overlapping portion 11 is formed, and the connected sewing portion 13 is formed by sewing with a sewing machine or the like at predetermined positions from the end edges 2a and 2a of the skin materials 2 and 2.
As a result, the two skin materials 2 and 2 are connected by the connecting sewing portion 13.
Next, as shown in FIG. 3 (b), the edge portions 2 a and 2 a of the respective skin materials 2 and 2 are folded back from the connection sewing portion 13 to provide the folded portions 31 and 31, and the folded portions 31 and 31. The non-woven fabric 12 is applied to the edge portions 2a and 2a of the skin materials 2 and 2 so as to cover the connected sewn portion 13.
Then, the decorative portions 32 are formed by sewing the folded portions 31 and 31 from the outside of the nonwoven fabrics 12 and 12 with a sewing machine or the like.
As a result, as shown in FIG. 3 (a), the two skin materials 2, 2 are connected by the connecting sewing portion 13, and the decorative sewing portions 32, 32 are formed on both sides thereof.
Liquid foamable resin is injected into the inside of the skin materials 2, 2 thus sewn three-dimensionally and integrated with the skin material by foaming.

According to this sewing structure 30, the decorative sewing portions 32, 32 are sewn with the nonwoven fabric 12 applied to the inside, so that the needle holes are closed by the nonwoven fabric, and leakage of the foamable resin is prevented. The
Further, the connecting and sewing portion 13 for connecting the skin materials 2 and 2 is located in the folded portions 31 and 31 where the edges 2a and 2a of the skin materials 2 and 2 are folded, and the outer sides thereof are the decorative sewing portions 32 and 32. Since the entrance portions of the folded portions 31 and 31 are crimped and closed, the penetration of the foamable resin into the folded portions 31 and 31 is prevented, and the decorative stitched portions 32 and 32 are folded back from the needle holes. The penetration of the foamable resin into the portions 31 and 31 is also prevented by overlapping the non-woven fabric 12 and sewing it.

  According to such a sewing structure 30, the design of the headrest 1, which is a skin-integrated foam molded body, can be enhanced by the decorative sewing portions 32, 32, and the decorative sewing portions 32, 32 and the connecting sewing portion 13 can be formed after forming. There is no need for post-processing to remove the foamable resin leaked from the stitched parts, etc., and the molding efficiency can be increased and production can be performed efficiently.

  The nonwoven fabric 12 used for such a sewing structure 30 may also have the same physical properties as the nonwoven fabric 12 used for the sewing structures 10 and 20 already described.

Examples of the present invention will be described below together with reference examples and comparative examples, but the present invention is not limited to these examples.

< Reference Example 1 >
A skin material was prepared by laminating a synthetic polyurethane as a surface fabric with a flexible polyurethane foam having a thickness of 5 mm and a hardness of 35 N (JIS K6400-2) by a frame lamination method. Two pieces of this skin material were cut into a rectangle of 300 mm length and 200 mm width, and three sides were sewn with an industrial sewing machine as shown in FIG. At this time, the nonwoven fabric 1 was provided in the sewing part.
In this evaluation sample, a foamed resin (100 parts by weight of polyether polyol, 70 parts by weight of a mixture of TDI-80 and polymeric MDI as polyisocyanate, dimethylethanolamine (2-dimethylaminoethanol, DMEA) as a reactive catalyst) 2.5 parts by weight, 1.0 part by weight of triethylenediamine (TEDA) as a non-reactive catalyst, 3.5 parts by weight of water as a blowing agent and 1 part by weight of silicone oil as a foam stabilizer) are injected from an injection nozzle. The foamed molded body integrated with the evaluation sample was obtained by foaming and curing.

<Example 2>
A skin material was prepared by laminating a synthetic polyurethane as a surface fabric with a flexible polyurethane foam having a thickness of 5 mm and a hardness of 35 N (JIS K6400-2) by a frame lamination method. Two pieces of this skin material were cut into rectangles of 300 mm in length and 200 mm in width, and three sides were sewn with an industrial sewing machine as shown in FIG. 1 using a polyester thread to prepare a bag-like evaluation sample. At this time, the nonwoven fabric 2 was provided in the sewing part.
In addition, foamed resin was inject | poured into this evaluation sample by the method similar to the said Experimental example 1, and the foaming molding integrated with the evaluation sample was obtained.

<Example 3>
A skin material was prepared by laminating a synthetic polyurethane as a surface fabric with a flexible polyurethane foam having a thickness of 5 mm and a hardness of 35 N (JIS K6400-2) by a frame lamination method. Two pieces of this skin material were cut into rectangles of 300 mm in length and 200 mm in width, and three sides were sewn with an industrial sewing machine as shown in FIG. 2 using a polyester thread to prepare a bag-like evaluation sample. At this time, the nonwoven fabric 2 was provided in the sewing part.
In addition, foamed resin was inject | poured into this evaluation sample by the method similar to the said Experimental example 1, and the foaming molding integrated with the evaluation sample was obtained.

<Example 4>
A skin material was prepared by laminating a synthetic polyurethane as a surface fabric with a flexible polyurethane foam having a thickness of 5 mm and a hardness of 35 N (JIS K6400-2) by a frame lamination method. Two pieces of this skin material were cut into a rectangle of 300 mm length and 200 mm width, and three sides were sewn with an industrial sewing machine as shown in FIG. At this time, the nonwoven fabric 2 was provided in the sewing part.
In addition, foamed resin was inject | poured into this evaluation sample by the method similar to the said Experimental example 1, and the foaming molding integrated with the evaluation sample was obtained.

<Comparative Example 1>
A skin material was prepared by laminating a synthetic polyurethane as a surface fabric with a flexible polyurethane foam having a thickness of 5 mm and a hardness of 35 N (JIS K6400-2) by a frame lamination method. Two pieces of this skin material were cut into a rectangle of 300 mm length and 200 mm width, and three sides were sewn with an industrial sewing machine as shown in FIG. At this time, the nonwoven fabric was not provided in the sewing part.
In addition, foamed resin was inject | poured into this evaluation sample by the method similar to the said Experimental example 1, and the foaming molding integrated with the evaluation sample was obtained.

Nonwoven fabrics used in the above experimental examples are as follows.
Nonwoven fabric 1: PET spunlace having a basis weight of 80 g / m ² and an average fiber diameter of 15.0 μm.
Nonwoven fabric 2: Melt blown made of polybutylene terephthalate (PBT average fiber diameter 3.5 μm) having a basis weight of 20 g / m ^{2 on} one side of a styrene elastomer resin meltblown nonwoven fabric (SEPS average fiber diameter 4.5 μm) having a basis weight of 25 g / m ² A two-layer laminate nonwoven fabric obtained by thermocompression bonding a nonwoven fabric with hot embossing. Air permeability (JIS-L1096) is 12.5cc / ^cm 2 / s, water pressure resistance (JIS-L1092) is 529mmH ₂ O, a porous material automatic pore based on the bubble point method of pore size (ASTMF-361-80 The average value of the measuring apparatus Palm Porometer POROUS MATERIAL, INC.) Is 12.1 μm.

About the foaming molding integrated with the evaluation sample obtained in the above Experimental Examples 1 to 5, the bleeding prevention property at the sewing portion was visually evaluated. The evaluation criteria are as follows.
(Double-circle): The injection | pouring urethane does not ooze out from a sewing part at all.
◯: There is a slight exudation of the injected urethane from the sewing part, but there is no problem in the surface appearance.
X: The seepage of the injected urethane from the sewing part is remarkable, and the surface appearance is poor.

According to one embodiment of the sewing structure of the skin integral foam molding skin material of the present invention, (a) is a partially enlarged sectional view of the sewing portion shown in the state of injecting a foamable resin, (b) in the sewing start state FIG. According to another embodiment of the sewing structure of the skin integrated foam molding skin material of the present invention, (a) is a partially enlarged sectional view of a sewing portion in a state where a foamable resin is injected, and (b) is a connected sewing portion. (C) is the elements on larger scale which show the sewing state of a decoration sewing part. It concerns on another one Embodiment of the sewing structure of the skin material for foam integrated molding of this invention, (a) is the elements on larger scale of the sewing part in the state which inject | pours foaming resin, (b) is decorative sewing (C) is the elements on larger scale which show the sewing state of a connection sewing part. It is a schematic sectional drawing of the headrest for vehicles of an example of the forming object to which the sewing structure of the skin material for skin integral foaming of this invention is applied. It is a cross-sectional view of the inside-up state of the sewing structure of the skin material for conventional skin integral foam molding. It is a partial expanded sectional view of the foaming resin injection state of the conventional sewing structure.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Sewing structure of skin material for integral foam molding 11 Superposed part 12 Non-woven fabric 13 Linked sewing part 20 Sewing structure of skin material for integral foam molding 21 Decorative sewing part 30 Sewing structure of skin material for integral foam molding 31 Folding part 32 Decorative sewing part 1 Headrest (molded body)
2 Skin material 2a Edge 3 Surface fabric 4 Soft polyurethane foam 5 Core material (insert part)
6 Sewing part 7 Seal part 8 Opening part

Claims (4)

It is a sewing structure of an outer skin integral foam molding material that is sewn to the outer shape of the molded body and injects a liquid foamable resin into the inside to foam and integrate,
The skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam adhered to the inside of the surface fabric,
The superficial fabrics at the edges of the skin material are overlapped to form an overlapped portion, a non-woven fabric is provided covering the outside of the overlapped portion, the non-woven fabric is a melt blown non-woven fabric, and a thermoplastic elastomer resin is used. It is composed of a laminate of two or three layers obtained by thermally bonding a nonwoven fabric made of polybutylene terephthalate or polypropylene to at least one surface or both surfaces of the nonwoven fabric, and has a water pressure resistance of 450 mmH ₂ O or more and an average pore size. A sewing structure of a skin material for foam integrated integral foaming, characterized in that it is 0.1 to 20 μm, and is formed by sewing the overlapping portion from the outside of the nonwoven fabric to provide a connected sewing portion.   The skin material for skin-integrated foam molding according to claim 1, wherein a decorative sewing portion is formed by sewing the edge portion of the non-woven fabric and each skin material on both sides sandwiching the connection sewing portion. Sewing structure. It is a sewing structure of an outer skin integral foam molding material that is sewn to the outer shape of the molded body and injects a liquid foamable resin into the inside to foam and integrate,
The skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam adhered to the inside of the surface fabric,
The surface fabrics at the edge of the skin material are overlapped to form an overlapped portion, and a stitched portion is formed by sewing at the overlapped portion, and the edge portion of each skin material is formed from the connected stitched portion. Are provided on the at least one surface or both surfaces of the nonwoven fabric made of a thermoplastic elastomer resin. It is composed of a two-layer or three-layer laminate formed by thermally bonding a nonwoven fabric made of terephthalate or polypropylene, and has a water pressure resistance of 450 mmH ₂ O or more and an average pore size of 0.1 to 20 μm. Each of the folded portions is sewn to form a decorative sewing portion, and the foamable resin from the decorative sewing portion and the connected sewing portion is A sewing structure for a skin material for integral foam molding, which is configured to prevent leakage. It is a sewing structure of an outer skin integral foam molding material that is sewn to the outer shape of the molded body and injects a liquid foamable resin into the inside to foam and integrate,
  The skin material is composed of at least a surface fabric disposed outside the molded body and a polyurethane foam adhered to the inside of the surface fabric,
  The edges of the skin material are arranged with a space between them, and a nonwoven fabric is stacked on the inner polyurethane foam, and the nonwoven fabric is disposed so as to straddle between the edges. The nonwoven fabric is a melt blown nonwoven fabric, and a thermoplastic elastomer resin. It is composed of a laminate of two or three layers formed by thermally bonding a nonwoven fabric made of polybutylene terephthalate or polypropylene to at least one side or both sides of a nonwoven fabric made of ₂ In addition to being O or more, the average pore size is 0.1 to 20 μm, and the decorative sewing parts are formed by passing through the nonwoven fabric at predetermined positions from the edge of each skin material and sewing the decorative sewing parts respectively. Connected surface fabrics of the skin material are overlapped and the edge side is sewn from the decorative sewing portion to form a connected sewing portion, and leakage of the foamable resin from the decorative sewing portion and the connected sewing portion is prevented. A sewing structure for a skin material for integral foam molding, characterized in that it is configured as described above.

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