JP5784947B2 - Sheet material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a sheet material excellent in design properties and cushioning properties used for, for example, vehicle interior materials and furniture, and a manufacturing technique thereof.

Conventionally, as a sheet material used for, for example, a vehicle interior material or furniture, a sheet material in which a surface material is laminated on the surface of a polyurethane foam is often used. In addition, a technique is known in which a fiber base material having elasticity is laminated on the surface of a polyurethane foam, and this integrated laminate is partially heat-compressed to form a concavo-convex pattern on the surface (for example, (See Patent Document 1).
At this time, as a means for forming an uneven pattern on the surface of the sheet material, the flat type embossing allows batch production, and the sheet material can be produced only on a single sheet instead of being continuous. It will be bad. In addition, when trying to increase production efficiency by embossing a rotary type that can be produced continuously, there is a problem that uneven patterns are not deeply formed on the surface of the sheet material laminated with polyurethane foam having an air layer. Is also disclosed in which an uneven pattern is formed on the surface of the heated embossed rose and a heat roll (see, for example, Patent Document 2).

On the other hand, as a technique for forming a concavo-convex pattern on the surface of the sheet material, a concavo-convex shape is formed in advance on the surface of the sponge body, and a stretchable fabric is attached along the concavo-convex surface and pressed with a concavo-convex pattern. Then, a technique for bonding and integrating is also known (for example, see Patent Document 3).
In addition, when forming an uneven shape on the surface of the polyurethane foam and laminating and integrating the sheet-like surface material on the uneven surface, the uneven surface side of the polyurethane foam is heated and melted to be integrated with the surface material. In addition, a technique (for example, see Patent Document 4) in which frame lamination is performed using an attachment having a shape that meshes with an uneven shape is also known.

Japanese Utility Model Publication No. 61-26044 JP 2007-276285 A Japanese Utility Model Publication No. 54-35182 JP-B-1-35735

  However, as in the techniques of Patent Document 1 and Patent Document 2, after a surface material is laminated on the surface of polyurethane foam, the integrated laminate is partially heat-compressed to form an uneven pattern on the surface of the sheet material. In addition, it is necessary to press at a high temperature in order to form a concavo-convex pattern, and there is a problem in that the texture of the surface material is damaged, especially when a soft surface material is used. was there. In addition, when such a heat press is performed, a relatively clear uneven pattern is formed on the surface of the sheet material, and it is impossible to form an uneven pattern that gives a soft and soft impression with the outline of the uneven pattern blurred. There was also a problem.

  In addition, as in the technique of Patent Document 3, a method for providing a concave / convex mold following the concave / convex shape of the sponge body and bonding and integrating it requires providing a separate concave / convex mold corresponding to the concave / convex shape of the sponge body. In addition, there is a problem that the positioning is not easy and takes time and at the same time increases the equipment cost. Furthermore, as in the technique of Patent Document 4, when the frame laminate is made, the frame laminate itself can be manufactured while continuously flowing the work, so that the production efficiency can be improved, but the assistance of the attachment is required. It is necessary to prepare a dedicated attachment according to the uneven shape of the foam, and because the uneven surface side of the polyurethane foam is heated and melted, it is difficult for the burner to reach the inside of the recess, resulting in uneven melting. There was a problem that the peel strength between the surface material and the polyurethane foam was insufficient.

  Therefore, in the present invention, when forming a concavo-convex pattern on the surface of a laminate in which a polyurethane foam and a surface material are laminated, it is possible to form a concavo-convex pattern with a soft impression as a whole without damaging the texture of the surface material. A sheet material that does not require an auxiliary means such as an attachment tailored to the uneven shape of the polyurethane foam, but also satisfies the peel strength of the surface material and the polyurethane foam, while adopting a frame laminate with high production efficiency. It is an object of the present invention to provide a method for manufacturing the same and a method for manufacturing the same.

  In order to achieve the above object, the present invention is a polyurethane foam comprising a sheet material in which a surface material is laminated on the surface of a polyurethane foam having a concavo-convex shape formed on the surface, and the surface material can be frame-laminated to a skin material. Is formed on the surface of the polyurethane foam, and the center distance a between the convex part and the convex part is 25 to 60 mm, and the difference b (height difference) between the maximum height of the convex part and the minimum height of the concave part. The surface interval is set to 1/10 to 1/3 of the center interval a, and the surface material is laminated on the uneven surface of the polyurethane foam by frame lamination in which flame is applied to the polyurethane foam side of the surface material that can be frame laminated as the sheet material. I made it.

Here, the present inventors have obtained the required peel strength between the polyurethane foam and the surface material when laminating the surface material with the frame laminate on the uneven surface of the polyurethane foam on which the uneven shape has already been formed. In order to create a design with a soft and soft impression, with the contours of the concavo-convex pattern formed on the surface of the material soft, pay attention to the concavo-convex shape of the polyurethane foam as the biggest point, and the spacing between the ridges In addition, a number of peel tests and design evaluations were performed by varying the difference (height difference) between the maximum height of the convex portion and the minimum height of the concave portion.
As a result, the center interval a between the convex portion and the convex portion is 25 to 60 mm, and the difference b (height difference) between the maximum height of the convex portion and the minimum height of the concave portion is set to 1/10 to 1/3 of the central interval a. In some cases, it was found that the required peel strength was obtained, and that the texture of the surface material remained, and the contour of the concavo-convex pattern formed on the surface of the sheet material was soft and soft. .

As the surface material, for example, a material obtained by laminating a skin material (synthetic leather, artificial leather, woven fabric, knitted fabric, woolen fabric, etc.) having a constant load elongation of 10% or more and a polyurethane foam capable of frame lamination can be used. If the constant load elongation of the skin material is less than 10%, for example, the followability of the surface material in the recesses formed in the polyurethane foam is deteriorated, the adhesiveness in the same part is deteriorated, and wrinkles are generated. However, if the constant load elongation is 10% or more, there is no such problem.
Here, the constant load elongation is the initial gripping interval of the gripping interval measured after fixing the upper part of a 50 mm wide test piece, setting the gripping interval to 100 mm, and applying a load of 29.4 N to the lower part for 5 minutes. The elongation percentage with respect to is measured.
In addition, as a method for forming the uneven shape on the surface of the polyurethane foam, it may be formed by so-called profile processing, may be formed by a two-dimensional cutter, or may be formed by other means.

  Further, in the method for producing the sheet material as described above, the center distance a between the convex portion and the convex portion is 25 to 60 mm on the surface of the polyurethane foam, and the maximum height of the convex portion and the minimum height of the concave portion. A step of forming a concavo-convex shape in which the difference b (height difference) is 1/10 to 1/3 of the center interval a, and a step of forming a surface material by laminating polyurethane foam capable of frame lamination on the skin material A step of melting a part of the surface of the foam by applying a flame to the frame-laminable polyurethane foam side of the surface material, and combining the melt surface of the surface material and the uneven surface of the polyurethane foam with a roll It was made to comprise from the process of laminating | stacking a surface material on a polyurethane foam by crimping | bonding.

In this way, a concavo-convex shape is formed on the surface of the polyurethane foam such that the center distance a between the convex part and the convex part is 25 to 60 mm and the height difference b between the convex part and the concave part is 1/10 to 1/3 of the center distance a. In addition, by laminating the surface material on the uneven surface with a frame laminate, the production efficiency is improved and the necessary peel strength is obtained, and the surface material is formed on the surface of the sheet material while leaving the texture. The contour of the concavo-convex pattern is soft and soft and the design is soft.
In addition, when laminating the frame, by applying a flame to the polyurethane laminate-side surface of the surface material having no irregularities, it becomes difficult to cause melting unevenness, and the peel strength can be increased.

The surface of the sheet material is laminated on the surface of the sheet material by laminating a surface material formed by laminating a polyurethane foam that can be laminated to the skin material and frame on the surface of the polyurethane foam. As a result, it is possible to form a concavo-convex pattern having a soft and soft impression without impairing the texture of the sheet, and to obtain a sheet material that sufficiently satisfies the peel strength between the surface material and the polyurethane foam.
Further, since the continuous production is possible by laminating the surface material by frame lamination, the production efficiency can be increased.

It is explanatory drawing of the shaping | molding method of the sheet material which concerns on this invention. It is explanatory drawing of the sheet material which concerns on this invention. It is explanatory drawing of the uneven | corrugated shape of the polyurethane foam which concerns on this invention. It is explanatory drawing which shows an example at the time of forming an uneven | corrugated pattern with embossing etc. with respect to a laminated integrated product.

  In the present invention, when forming a concavo-convex pattern on the surface of a laminate in which a polyurethane foam and a surface material are laminated, the surface material is a laminate of a polyurethane foam that can be laminated with a skin material, and the texture of the skin material is impaired. It is possible to provide a sheet material and a method for producing the same that can sufficiently form a concavo-convex pattern with a soft impression as a whole, and sufficiently satisfy the peel strength between the surface material and the polyurethane foam. A surface material is laminated by frame laminating after forming a concavo-convex shape of a predetermined pattern on the surface.

  That is, when forming a concavo-convex pattern on the surface of the laminate in which the polyurethane foam 2 and the surface material 3 are laminated to form a sheet material, when the concavo-convex pattern is formed by embossing after lamination and integration, for example, as shown in FIG. As described above, the contour of the concavo-convex pattern is clear, the design of the impression that the whole atmosphere is soft cannot be molded, the texture of the surface material is further impaired, and the width of the expression of the design is limited was there.

  Therefore, the present inventors have firmly laminated the surface material and polyurethane foam without damaging the texture of the surface material constituting the surface material, and the contour of the uneven pattern is dim and the entire design is soft and soft. In order to achieve this, it is considered necessary to form an uneven shape on the surface of the polyurethane foam in advance, and then laminate a surface material on the surface. We focused on it as an important point in terms of sex.

  For this reason, the present inventors, in the concavo-convex shape formed on the surface of the urethane foam 2 shown in FIG. 3, the difference between the convex portion-center distance a and the maximum height of the convex portion and the minimum height of the concave portion. b, the relationship between the two and the like were changed in various ways, the polyurethane foam 2 and the surface material 3 were laminated and integrated, and the peel strength and the design were tested. The center interval a between the convex portion and the convex portion was 25 to 60 mm. When the difference b (height difference) between the maximum height of the convex portion and the minimum height of the concave portion is 1/10 to 1/3 of the center interval a, sufficient peel strength even when the surface material 3 is joined by frame lamination Furthermore, it was found that the design of the soft and soft impression that has never been obtained is obtained on the surface of the sheet material due to the rough outline of the concavo-convex pattern. In addition, it was confirmed that the production efficiency would not be lowered because the continuous production was possible by adopting the lamination by frame lamination.

Therefore, a method for forming such a sheet material will be described with reference to the drawings.
First, as shown in FIG. 3, an uneven shape is formed on the surface of the polyurethane foam 2. At this time, the concavo-convex shape has a convex portion-to-center distance a of 25 to 60 mm, and a difference b (height difference) between the maximum height of the convex portion and the minimum height of the concave portion is 1 / of the central interval a. 10 to 1/3.
When the center interval a is less than 25 mm, the surface material 3 is less likely to follow the uneven shape of the polyurethane foam 2 and the peel strength is inferior, and the uneven shape of the polyurethane foam 2 cannot be expressed on the surface of the sheet material. If it exceeds, design will be poor.
Further, if the height difference b is less than 1/10 of the center interval a, the uneven feeling is poor and a design cannot be obtained. If the difference b exceeds 1/3, the surface material 3 has the uneven shape of the polyurethane foam 2. It becomes difficult to follow, and sufficient peel strength cannot be obtained.
In addition, it becomes difficult for the surface material 3 to follow the uneven shape of the polyurethane foam 2, in particular, in the concave portion, it is difficult for the surface material 3 and the polyurethane foam 2 to adhere to each other. Therefore, sufficient peel strength cannot be obtained. Moreover, wrinkles are generated in the concave portions, and the uneven shape of the polyurethane foam 2 cannot be expressed on the surface of the sheet material, resulting in poor design.
The means for forming such a concavo-convex shape on the polyurethane foam 2 may be so-called profile processing in which a middle portion of the polyurethane foam deformed by using a pair of concavo-convex molds is planarly divided, using a two-dimensional cutter. Then, the surface may be formed with a concavo-convex shape, or by other means.
As described above, when the maximum thickness of the polyurethane foam 2 having a concavo-convex shape formed on the surface is about 10 to 30 mm, the polyurethane foam 2 has excellent cushioning properties when used for a vehicle interior material or furniture.

On the other hand, the surface material 3 is formed. The surface material 3 is obtained by laminating a polyurethane foam 5 that can be laminated to a frame on the back side of a skin material 4 made of, for example, synthetic leather, artificial leather, woven fabric, knitted fabric, woolen fabric, or the like. These layers are laminated by an adhesive laminate, a frame laminate or the like.
Here, as the polyurethane foam 5 that can be frame-laminated, a polyurethane foam that has been conventionally used for frame laminating can be used.
Moreover, the thickness of the polyurethane foam 5 that can be frame laminated before lamination is preferably about 1 to 3.5 mm, and the remaining thickness of the polyurethane foam 5 after lamination is preferably 0.5 to 3 mm. If the remaining thickness is less than 0.5 mm, sufficient peel strength is difficult to obtain, and if it exceeds 3 mm, the uneven shape formed in the polyurethane foam 2 is difficult to appear on the surface, the feeling of unevenness is poor, and the design is impaired. There is a risk that.

  At this time, the constant load elongation rate of the skin material 4 is desirably 10% or more. This is because when the constant load elongation is less than 10%, the followability of the skin material 4 in the concave portions of the polyurethane foam 2 is deteriorated when laminated on the concave and convex surface of the polyurethane foam 2, and the adhesiveness in the same portion is reduced. It is because it gets worse or wrinkles are generated in the recesses on the surface of the sheet material 1.

  Then, when laminating the polyurethane foam 2 and the surface material 3 having a concavo-convex shape on the surface, as shown in FIG. 1, a flame such as a burner is applied to the polyurethane foam 5 side of the surface material 3 on which the frame can be laminated. Part of the surface of 5 is melted, the melt surface of the surface material 3 and the uneven surface of the polyurethane foam 2 are combined and passed between the pair of rolls 7, and both are laminated and integrated to form the sheet material 1.

  In such a molding method, the surface material 3 and the polyurethane foam 2 as shown in FIG. 2 are integrated, and at this time, the outline of the concavo-convex pattern is blurred, so that the whole atmosphere has a soft and soft design. Material 1 could be molded. Moreover, the peel strength between the surface material 3 and the polyurethane foam 2 was sufficiently satisfactory, and the surface of the sheet material 4 was not damaged, and no wrinkles or the like were observed on the surface of the sheet material, particularly in the recesses.

[Examples 1 to 4, Comparative Examples 2 to 7]
The uneven | corrugated shape which has the center space | interval a and the height difference b shown in Table 1 and 2 was continuously formed in the surface of the polyurethane foam, respectively. Also, a surface material was prepared by laminating a polyurethane foam having a thickness of 2.5 mm on a knitted fabric having a constant load elongation of 20% by frame lamination. At this time, the remaining thickness of the polyurethane foam capable of frame lamination was 2 mm.
Next, the surface material and the uneven surface of the polyurethane foam were laminated by frame lamination to obtain a sheet material. At that time, by applying a flame to the polyurethane foam side of the surface material that can be laminated to the frame, the surface of the foam is melted, and the melted surface of the surface material and the uneven surface of the polyurethane foam are combined and pressed with a roll. The surface material and polyurethane foam were laminated. In addition, the remaining thickness of the polyurethane foam which can carry out the frame lamination of the surface material of the obtained sheet | seat material was 1.5 mm.
[Comparative Example 1]
A sheet material was obtained in the same manner as described above except that a flame was applied to the uneven surface of the polyurethane foam to laminate the surface material and the uneven surface of the polyurethane foam.

The following evaluation was performed about the sheet | seat material obtained in Examples 1-4 and Comparative Examples 1-7. The results are shown in Tables 1 and 2.
〔Evaluation method〕
(1) Peel test In the sample piece which cut | disconnected the obtained sheet | seat material in width 25mm, 180 degree peel strength of the surface material with respect to the polyurethane foam in which the uneven | corrugated shape was formed on the surface was measured.
The evaluation criteria are as follows.
○
Peel strength is 2.0 N / 25 mm or more, or polyurethane foam is broken x Peel strength is less than 2.0 N / 25 mm (2) Designability Evaluation criteria are as follows.
○ The surface material follows the uneven shape of the polyurethane foam, and the surface of the sheet material has a soft and uneven pattern that is soft as a whole. × The surface material does not follow the uneven shape of the polyurethane foam, and the concave portion on the surface of the sheet material Wrinkles will occur and the design will be inferior.
Alternatively, the surface material follows the uneven shape of the polyurethane foam, but the texture is poor and the design cannot be obtained.

  In Examples 1 to 4, the center interval a between the convex portion and the convex portion is 25 to 60 mm, the height difference b between the convex portion and the concave portion is set to 1/10 to 1/3 of the center interval a, and the surface material and polyurethane When laminating foam with frame laminate, the surface material was laminated by applying flame to the polyurethane laminate side that can be laminated to the surface material, so the surface material followed the uneven shape of the polyurethane foam, and sufficient peel strength was obtained, And the sheet material which has the uneven | corrugated pattern of the soft impression which was soft as a whole was obtained.

  On the other hand, in Comparative Example 1, the surface material was laminated by applying a flame to the uneven surface of the polyurethane foam, but it was difficult for the flame to reach the recess of the polyurethane foam, resulting in uneven melting, and the surface material and While the peel strength of the polyurethane foam was insufficient, wrinkles were formed in the recesses of the obtained sheet material, and the design properties were inferior.

Moreover, in Comparative Examples 2-6, as an uneven | corrugated shape formed in the surface of a polyurethane foam, the space | interval a of a convex part and a convex part is other than 25-60 mm, and the height difference b of a convex part and a recessed part is 1 / of the center space | interval a. When the surface material is other than 10/3, the surface material does not follow the uneven shape of the polyurethane foam, in particular, the adhesion of the concave portion is insufficient, wrinkles are generated there, and the peel strength is inferior or peeled. Even though the strength was sufficient, the sheet material had poor texture and poor design.
As a result, the effectiveness of the present invention was confirmed.

  The present invention is not limited to the above embodiment. What has substantially the same configuration as the matters described in the claims of the present invention and exhibits the same operational effects belongs to the technical scope of the present invention.

  Since a concavo-convex pattern with a soft and soft impression that is not present in the past is formed, widespread use in, for example, vehicle interior materials and furniture is expected.

DESCRIPTION OF SYMBOLS 1 ... Sheet material, 2 ... Polyurethane foam, 3 ... Surface material, 4 ... Skin material, 5 ... Polyurethane foam which can be flame-laminated, 6 ... Burner etc. 7 ... Roll.

Claims (2)

A sheet material in which a surface material is laminated on the surface of a polyurethane foam having a concavo-convex shape formed on the surface, wherein the surface material is obtained by laminating a polyurethane foam capable of frame lamination on a skin material, and the polyurethane The uneven shape of the foam surface is such that the center distance a between the convex part and the convex part is 25 to 60 mm, and the difference b (height difference) between the maximum height of the convex part and the minimum height of the concave part is 1/10 to 1 of the center distance a. The sheet material is characterized in that the surface material is laminated on the uneven surface of the polyurethane foam by frame lamination in which a flame is applied to the frame foamable polyurethane foam side of the surface material. Wood. A method for producing a sheet material in which a surface material is laminated on the surface of a polyurethane foam having a concavo-convex shape formed on the surface, wherein the center distance a between the convex portion and the convex portion is 25 to 60 mm on the surface of the polyurethane foam. The step of forming a concavo-convex shape in which the difference b (height difference) between the maximum height of the convex portion and the minimum height of the concave portion is 1/10 to 1/3 of the center interval a, and urethane that can be frame laminated to the skin material A step of forming a surface material by laminating foam, a step of melting a part of the surface of the foam by applying a flame to a urethane foam side of the surface material that can be frame laminated, and a melting surface of the surface material And a step of laminating the surface material onto the polyurethane foam by pressing the surface of the polyurethane foam with the concavo-convex surface of the polyurethane foam and pressing with a roll. .

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