JP6752920B2 - Manufacturing method of laminated sheet having uneven pattern on the surface - Google Patents

Description

The present invention relates to a method for producing a laminated sheet in which a flexible surface member is laminated and integrated with a flexible polyurethane foam and has an uneven pattern formed by heat compression molding on the surface.

As a skin material used for a seat skin or a furniture skin of a vehicle such as an automobile, there is a laminated sheet having an uneven pattern on the surface.
The laminated sheet having the uneven pattern on the surface is manufactured by laminating and integrating a flexible surface member on a flexible polyurethane foam and heat-compressing the surface with a pressurizing device having the uneven pattern formed on the surface.

However, the conventional laminated sheet having an uneven pattern on the surface must have an uneven compression residual strain (JISK6400-4: 70 ° C. × 22 hours × 50% after compression) of 25 to 50% as a flexible polyurethane foam. Since the pattern cannot be clearly formed, there is a problem that the compression distortion due to the long-term use of the product is large, and the uneven pattern becomes unclear due to the long-term use and the aesthetic appearance is deteriorated.

JP-A-2007-331222

The present invention has been made in view of the above points, and even if a flexible polyurethane foam having a smaller residual compression strain than the conventional one is used, the uneven pattern can be made clear and the compression strain due to long-term use of the product can be reduced. It is an object of the present invention to provide a method for manufacturing a laminated sheet having an uneven pattern on its surface, which can be formed and can maintain a good uneven pattern even after long-term use.

The invention of claim 1 is a laminated sheet in which a flexible surface member is laminated and integrated with a flexible polyurethane foam and has an uneven pattern formed by heat compression molding on the surface, wherein the flexible polyurethane foam has an ester group. When the polyol having another polyol is contained together with the polyol having an ester group, when the polyol having an ester group contains at least one of a phosphate ester flame retardant or an ester additive, the polyol having an ester group is not contained and the phosphoric acid ester flame retardant or Either of the cases where at least one of the ester-based additives is contained, the ester value (JIS K0070 compliant) in these cases is 40 to 400 mgKOH / g, and the surface of the flexible polyurethane foam is heat-compressed. The surface of the laminated sheet has the unevenness formed by the unevenness on the surface of the flexible polyurethane foam, and the unevenness of the unevenness pattern formed on the surface of the laminated sheet. The height of the portion or the depth of the recess is 3 to 30 mm.
According to the first aspect of the present invention, the flexible polyurethane foam has a square cross section of 50 mm on a side and a thickness of 10 mm, and a spacer of 5 mm is used to reduce the thickness of the flexible polyurethane foam to 50% of the original thickness. It is characterized by being composed of a flexible polyurethane foam which is heat-compressed at 80 ° C. for 240 seconds and has a molding ratio of 70 to 100% calculated by the following formula using the compressed thickness.
Molding rate (%) = [(original thickness-thickness after compression) / (original thickness-thickness of spacer)] x 100

According to the third aspect of the present invention, the surface of a laminated sheet in which a flexible surface member is laminated and integrated with a flexible polyurethane foam is thermally compressed by a pressurizing device having an uneven pattern formed on the surface to form an uneven pattern on the surface. In the method for producing a laminated sheet having, when the flexible polyurethane foam contains a polyol having an ester group and another polyol, the flexible polyurethane foam contains at least one of a phosphoric acid ester flame retardant or an ester additive together with the polyol having an ester group. In this case, it is either a case where it does not contain a polyol having an ester group and contains at least one of a phosphoric acid ester flame retardant or an ester additive, and the ester value (JIS K0070 compliant) in these cases is 40 to 400 mgKOH. / G, the surface member and the flexible polyurethane foam are welded by frame lamination, and the surface of the flexible polyurethane foam has irregularities shaped by the heat compression molding, and the lamination The surface of the sheet has the uneven pattern due to the unevenness on the surface of the flexible polyurethane foam, and the height of the convex portion or the depth of the concave portion of the uneven pattern formed on the surface of the laminated sheet is 3 to 3. It is characterized by being 30 mm.
According to the third aspect of the present invention, the flexible polyurethane foam has a square cross section of 50 mm on a side and a thickness of 10 mm, and a spacer of 5 mm is used to reduce the thickness of the flexible polyurethane foam to 50% of the original thickness. It is characterized by being composed of a flexible polyurethane foam which is heat-compressed at 80 ° C. for 240 seconds and has a molding ratio of 70 to 100% calculated by the following formula using the compressed thickness.
Molding rate (%) = [(original thickness-thickness after compression) / (original thickness-thickness of spacer)] x 100

According to the inventions of claims 1 and 2, a flexible polyurethane foam having an ester value (JIS K0070 compliant) of 40 to 400 mgKOH / g is used, so that even if a flexible polyurethane foam having a small compression residual strain is used. The uneven pattern can be made clear, the compression residual strain of the product is small, and a good uneven pattern can be maintained even after long-term use.

According to the inventions of claims 3 and 4, it is easy to obtain a laminated sheet having an uneven pattern on the surface, which has a clear uneven pattern on the surface, a small residual compression strain, and can maintain a good uneven pattern even after long-term use. Obtainable.

It is sectional drawing which shows a part of the laminated sheet which has the concavo-convex pattern of embodiment on the surface. It is schematic cross-sectional view which shows the manufacture of the laminated sheet which has an uneven pattern on the surface. It is sectional drawing which shows the other example of the uneven surface of the concave-convex shaping type.

Hereinafter, embodiments of the present invention will be described. The laminated sheet 10 having the uneven pattern shown in FIG. 1 on the surface is used for vehicle interior materials such as seat skins, door trims, furniture skins, etc., and the surface member 21 is formed on one side of the flexible polyurethane foam 11. 23 is laminated and integrated, and has an uneven pattern 23 formed by heat compression molding on the surface. The uneven pattern 23 is not limited to the one in which the convex portions 24 are arranged in a grid pattern, but may be one in which the convex portions 24 are arranged so as to form a required pattern, and the convex portions 24 and the concave portions 25 are arranged according to the required design. The arrangement of the above is determined. Further, the height of the convex portion 24 (depth of the concave portion 25) is preferably about 3 to 30 mm.

The flexible polyurethane foam 11 has an ester value (JIS K0070 compliant) of 40 to 400 mgKOH / g, more preferably 45 to 400 mgKOH / g, and compression residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22). Time x 50% after compression) consists of 1 to 15%. If the ester value is less than 40 mgKOH / g, the unevenness-forming property is lowered, while if it exceeds 400 mgKOH / g, the moisture and heat resistance of the urethane foam is deteriorated, which may not be suitable as a skin material for automobiles and the like. Further, when the compression residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 hours × 50% after compression) is less than 1%, the molding time required for uneven shaping tends to be long, and the molding cycle May be longer. On the other hand, when it exceeds 15%, the compression residual strain of the product becomes worse, and the protruding pattern is often liable to become unclear due to long-term use of the product, resulting in deterioration of the uneven design.

The flexible polyurethane foam 11 is formed from a polyurethane raw material containing a polyol, a foaming agent, a catalyst, a foam stabilizer, a polyisocyanate, and an appropriate additive. The density of the flexible polyurethane foam 11 (based on JIS K 7222: 1999) is 15 to 80 kg / m ³ , the hardness (based on JIS K 6400-2: 2004) is 60 to 200 N, more preferably 60 to 160 N, and the thickness is. It is preferably about 3 to 30 mm. If the hardness exceeds 200 N, the foam surface becomes too hard, and the cushioning property and tactile sensation as a laminated sheet deteriorate.

The polyol may be any of a polyether polyol, a polyester polyol, and a polyether ester polyol, and one or more of them may be used.
Polyether polyols include, for example, ethylene oxide (EO) in polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and shoe cloth. ), Polyether polyol to which alkylene oxide such as propylene oxide (PO) is added. If the polymer polyol is used in an amount of 50% or more of the polyol component, the hardness becomes too hard and the strain becomes worse.

The polyester polyol is, for example, polycondensed from an aliphatic carboxylic acid such as malonic acid, succinic acid or adipic acid, an aromatic carboxylic acid such as phthalic acid, and an aliphatic glycol such as ethylene glycol, diethylene glycol or propylene glycol. The polyester polyol thus obtained can be mentioned.
In addition, examples of the polyether ester polyol include those obtained by reacting the polyether polyol with a polybasic acid to form a polyester, or those having both a polyether and a polyester segment in one molecule.
In the present invention, the ester value of the flexible polyurethane foam 11 can be set in a specific range by using a polyol having an ester group, specifically a polyester polyol or a polyether ester polyol, as the polyol. It is more preferable in terms of improving shapeability and strain.

As the foaming agent, water or a hydrocarbon such as pentane can be used alone or in combination. In the case of water, carbon dioxide gas is generated during the reaction between the polyol and polyisocyanate, and the carbon dioxide gas causes foaming. The amount of the foaming agent is appropriate, but in the case of water, 1 to 8 parts by mass is suitable with respect to 100 parts by mass of the polyol.

As the catalyst, a known catalyst for flexible polyurethane foam can be used. For example, amine catalysts such as triethylamine and tetramethylguanidine, tin catalysts such as stanus octoate, and metal catalysts such as phenylmercury propionate or lead octenoate (also referred to as organic metal catalysts) can be mentioned. Can be done. A typical amount of catalyst is 0.1 to 2 parts by mass with respect to 100 parts by mass of polyol.

As the foam stabilizer, those known for flexible polyurethane foam can be used. For example, a silicone-based foam stabilizer, a fluorine-containing compound-based foam stabilizer, and a known surfactant can be mentioned. The general amount of the foam stabilizer is 0.5 to 3 parts by mass with respect to 100 parts by mass of the polyol.

As the polyisocyanate, an aliphatic or aromatic polyisocyanate having two or more isocyanate groups, a mixture thereof, and a modified polyisocyanate obtained by modifying them can be used. Examples of the aliphatic polyisocyanate include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate, and examples of the aromatic polyisocyanate include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalenediocyanate, and xylyl. Examples thereof include range isocyanate and polypeptide polyisocyanate (crude MDI). In addition, other prepolymers can also be used.

The isocyanate index is preferably 90 to 120. The isocyanate index is a value obtained by dividing the number of moles of isocyanate groups in polyisocyanate by the total number of moles of active hydrogen groups such as hydroxyl groups of polyol and water as a foaming agent multiplied by 100, and [NCO equivalent of polyisocyanate]. / Active hydrogen equivalent x 100].

Examples of appropriate additives include flame retardants, ester-based additives, colorants, auxiliary foaming agents, and the like. Flame retardants include halogenated polymers such as polyvinyl chloride, chloroprene rubber and chlorinated polyethylene, phosphoric acid esters and halogenated phosphoric acid ester compounds, organic flame retardants such as melamine resin and urea resin, antimony oxide and hydroxide. Examples thereof include inorganic flame retardants such as aluminum. In particular, a flame retardant composed of a phosphoric acid ester can increase the ester value of the flexible polyurethane foam 11 as well as improve the flame retardancy, but especially when the polyol uses only a polyether polyol, the ester value of the flexible polyurethane foam 11 can be increased. Within the scope of the present invention, the shapeability is improved. The general amount of the flame retardant is 2 to 30 parts by mass with respect to 100 parts by mass of the polyol.

The ester-based additive is used for adjusting the ester value of the flexible polyurethane foam 11, and examples thereof include rosin ester. In particular, when only a polyether polyol is used as the polyol and the flame retardant is not a phosphoric acid ester, the ester value of the flexible polyurethane foam can be easily made within the scope of the present invention by using an ester-based additive. Examples of the ester-based additive include rosin ester and acrylic acid ester. When an ester-based additive is used, the amount added varies depending on the type of polyol, the type of flame retardant, and the like, and examples thereof include 1 to 30 parts by mass with respect to 100 parts by mass of the polyol.
Examples of the auxiliary foaming agent include volatile solvents, methylene chloride (methylene chloride, CH ₂ Cl ₂ ), chlorofluorocarbon compounds (trichlorofluoromethane, dichlorodifluoromethane, etc.), liquefied carbon dioxide gas, and the like.

In the flexible polyurethane foam 11, a polyurethane raw material composed of the polyol, a foaming agent, a catalyst, a foam stabilizer, an appropriate additive (flame retardant, ester-based additive, etc.), polyisocyanate, etc. is mixed and reacted with a stirrer. It is formed by a known foaming method for foaming. Further, the flexible polyurethane foam 11 is preferably obtained by cutting a soft slab foam into a predetermined thickness. The soft slab foam is a flexible polyurethane foam obtained by reacting and foaming the polyurethane raw material at room temperature and atmospheric pressure, and is highly mass-producible and has a higher yield than molding.

The flexible polyurethane foam 11 is prepared by using a polyol having an ester group, by using a phosphoric acid ester-based flame retardant, by using an ester-based additive, or by using them in combination. The ester value (JIS K0070 compliant) can be 40 to 400 mgKOH / g.
Further, the compression residual strain of the flexible polyurethane foam 11 (JIS K 6400-4 6.2B method, 70 ° C. × 22 hours × after 50% compression) uses a polyol having an ester group as the polyol, and a large amount of polymer polyol. It is obtained by using a polyether polyol, a polyester polyol, or a polyether ester polyol without using (50% or more).

The surface member 21 is made of an appropriate material such as a knitted fabric, a woven fabric having flexibility and elasticity, and a non-woven fabric, and is selected according to the use of the laminated sheet. Specifically, the surface members are knitted fabrics such as tricots, jerseys, and double raschels, woven fabrics / non-woven fabrics made of fibers containing elastic fibers, and non-woven fabrics on which a large number of embossed portions are formed. It is preferable to use a non-woven fabric having elasticity, or a needle-punched non-woven fabric in which fibers are spirally crimped and have excellent elasticity.
The surface member 21 and the flexible polyurethane foam 11 are integrated by welding with a frame laminate or the like, or by an adhesive or the like as described later.
Depending on the use of the laminated sheet 10 having the uneven pattern on the surface, the back base cloth may be laminated and integrated on the back surface of the flexible polyurethane foam 11 on the opposite side of the surface member 21.
The laminated sheet 10 is preferably a three-layer composite sheet obtained by laminating a back base fabric, particularly a woven fabric or a non-woven fabric having low elasticity, on the back surface of the flexible polyurethane foam 11. Specifically, a non-woven fabric or woven fabric made of nylon / polyester having a basis weight of 30 g / m ² or more, or a knitted fabric of Queens is preferable. The presence of a backing fabric with low elasticity creates a firm feeling, which is preferable because the soft polyurethane foam shaped into irregularities weakens the force to return to smoothness.
The laminated sheet 10 having the uneven pattern on the surface is used after being formed into a predetermined shape by sewing or the like depending on the intended use. For example, in the case of the skin of a seat, the laminated sheet 10 having the uneven pattern on the surface is made into a bag shape by sewing or the like with the uneven pattern on the outside to cover the cushion body.

A method of manufacturing the laminated sheet 10 having the uneven pattern on the surface will be described. The method for manufacturing the laminated sheet 10 having the uneven pattern on the surface includes a laminating integration step and an uneven pattern shaping step.
In the laminating and integrating step, the surface member 21 is laminated and integrated on one side of the flexible polyurethane foam 11 by a known laminating and integrating method such as frame laminating and laminating using an adhesive, and (2-A) of FIG. ) Is obtained, and the laminated sheet 10A before shaping is obtained. When the back base cloth is used, the back base cloth is laminated in this step to obtain a laminated sheet having a three-layer structure before shaping.

The frame laminate is a method in which the surface of the flexible polyurethane foam 11 is melted by irradiation with a flame burner or the like, and the surface member 21 is laminated and welded on the molten surface. In the frame laminate, the surface of the flexible polyurethane foam 11 is usually melted with a flame burner or the like while continuously supplying the flexible polyurethane foam 11, and the surface member 21 is continuously laminated on the molten surface. It is done by molding. The temperature of the flame burner or the like is generally about 600 to 1300 ° C. When the back base cloth is used, after the surface member is welded, the other surface of the flexible polyurethane foam 11 is melted with a flame burner or the like to weld the back base cloth to the melted surface.
On the other hand, in a laminate using an adhesive, an adhesive is applied to at least one adhesive surface of the flexible polyurethane foam 11 and the surface member 21, and the flexible polyurethane foam 11 and the surface member 21 are sandwiched so as to sandwich the adhesive-coated surface. It is a method of stacking and adhering. As the adhesive, a hot melt adhesive or the like is used. When the back base cloth is used, the back base cloth is adhered to the other surface of the flexible polyurethane foam 11 with an adhesive.

In the uneven pattern shaping step, the uneven pattern is formed by heat-compressing the surface of the surface member 21 of the laminated sheet 10A before shaping with the uneven pattern shaping device having the uneven pattern formed on the surface. Examples of the heat compression by the unevenness shaping device in which the uneven pattern is formed on the surface include a heat pressing method using the uneven shaping type in which the uneven pattern is formed on the surface, a roll heat compression method using an embossed roll, and the like.

The heat pressing method will be described. In the hot pressing method, as shown in (2-B) of FIG. 2, the surface member 21 is uneven between the base 31 and the heatable uneven shaping mold 33 of the laminated sheet 10A before shaping. As shown in (2-C) of FIG. 2, the convex portion 35 of the concave-convex surface 34 of the concave-convex shaping mold 33 is arranged so as to face the concave-convex surface 34 of the shaping mold 33 and heated to a predetermined temperature. The surface member 21 of the laminated sheet 10A before shaping is heat-compressed to form an uneven pattern on the surface. The uneven surface 34 of the concave-convex shaping mold 33 is composed of a plurality of convex portions 35 and concave portions 36 formed at predetermined intervals. Further, the uneven shape shaping type 33 can be heated by arranging a hot plate on the back surface, by arranging a heating wire inside, or the like. The heating temperature of the uneven shaping mold 33 is preferably 170 to 210 ° C. The pressurization time for the laminated sheet 10A before shaping is preferably 60 to 400 seconds. Even when a laminated sheet having a three-layer structure in which the back base cloth is laminated is used as the laminated sheet 10A, the surface member 21 is heat-compressed so as to face the uneven surface 34 of the concave-convex shaping mold 33.

The concavo-convex surface of the concavo-convex shaping type may be a concavo-convex surface 34A having an R-shaped cross section as in the concavo-convex shaping type 33A shown in FIG. It is also possible to have a free design shape such that the compressed state is gradually changed by forming an obliquely tapered uneven surface 34B such as 33B. Even in this case, by using the polyurethane foam having good thermoformability of the present invention, it is possible to shape the shape along the uneven surface shape of the above-mentioned uneven shape shaping type.

On the other hand, in the roll heat compression method, the surface member 21 of the pre-formation laminated sheet 10A to be continuously supplied is heat-compressed by an embossed roll (not shown) having an uneven pattern on the surface and capable of heating. As a result, an uneven pattern is formed on the surface. The heating temperature of the embossed roll is preferably 180 to 220 ° C., and the supply rate of the preforming laminated sheet 10A is preferably about 1 to 10 m / min.

Using a polyurethane raw material prepared by blending the following polyols, foaming agents, catalysts, foam stabilizers, flame retardants, and polyisocyanates in the formulation shown in Table 1, the flexible polyurethane foams of Examples, Reference Examples, and Comparative Examples were prepared by the slab foaming method. Created. Ester value (JIS K0070 compliant), compression residual strain (JIS K 6400-4 6.2B method, 70 ° C. x 22 hours x 50% after compression), density for each of the flexible polyurethane foams of Examples, Reference Examples and Comparative Examples. (Compliant with JIS K7222) and hardness (compliant with JIS K 6400-2: 2004) were measured. The measurement results are shown in the middle of Table 1.

・ Polyester A: polyether polyol, molecular weight 3000, number of functional groups 3, hydroxyl value 56 mgKOH / g, product name: Sanniks GP3000, manufactured by Sanyo Kasei Kogyo Co., Ltd. ・ Polyol B: polyether ester polyol, number of functional groups 3, hydroxyl value 56 mgKOH / g , Product name: Actol L-50, manufactured by Mitsui Takeda Chemical Co., Ltd. ・ polyol C: polyester polyol, molecular weight 2500, number of functional groups 2.7, hydroxyl value 60.5 mgKOH / g, product name: polyol N2200, manufactured by Nippon Polyurethane Industry Co., Ltd.・ Foaming agent: Water ・ Auxiliary foaming agent: Methylene chloride ・ Amine-based catalyst: A mixture of triethylenediamine and dipropylene glycol with a weight ratio of 1: 2, product name: DABCO 33-LV, manufactured by Air Products Japan Co., Ltd. ・ Tin-based catalyst: Star Nas Octate, Product name: MRH-110, manufactured by Johoku Chemical Industry Co., Ltd. ・ Foam stabilizer: Silicone foam stabilizer, Product name: DABCO DC5160, manufactured by Air Products Japan Co., Ltd. ・ Flame retardant: Phosphate ester flame retardant, Product name: CR- 504L, manufactured by Daihachi Chemical Co., Ltd. ・ Polyisocyanate: toluene diisocyanate (2,4-TDI and TDI in which 2,6-TDI is 80:20), product name: TDI-80, manufactured by Nippon Polyurethane Industry Co., Ltd.

The flexible polyurethane foams of each Example and Comparative Example were cut to a thickness of 15 mm and continuously supplied, and the following surface members and back base cloth were laminated and integrated by frame lamination to prepare a laminated sheet before shaping. The supply rate of the flexible polyurethane foam is 20 m / min.
Surface member: Tricot, basis weight 300 g / m ² .
Back base cloth: non-woven fabric, material: nylon, basis weight 30 g / m ² .

The laminated sheet before shaping is heat-compressed from the surface member side by a heat press using the uneven shaping mold shown in FIGS. 2 (2-B) and (2-C), and examples and reference examples. , A laminated sheet having the uneven pattern of the comparative example on the surface was prepared. The plurality of convex portions formed in the concave-convex shape shape have a square cross section of 500 mm on a side, are formed of a columnar body having a height of 13 mm, and are arranged in a grid pattern with an interval of 40 mm. .. The heating temperature of the uneven shape shaping type is 180 ° C., and the pressurizing time is 240 seconds. For the laminated sheets having the uneven patterns of Examples, Reference Examples and Comparative Examples on the surface, the moldability of the uneven patterns on the surface and the molding rate after hot pressing were judged.
The moldability is judged by the molding rate after hot pressing. When the molding rate is 100 to 90% or more, it is "◎", when it is less than 90 to 70% or more, it is "○", and when it is less than 70% It was set as "x". The molding rate of urethane foam after hot pressing is as follows: Urethane foam having a square cross section with a side of 50 mm and a thickness of 10 mm is heat-compressed at 80 ° C. for 240 seconds using a spacer of 5 mm (the original thickness). (Compressed to 50%), and the thickness after compression was measured. The results are shown at the bottom of Table 1.
The molding rate was calculated by the following formula.
Molding rate (%) = [(original thickness-thickness after compression) / (original thickness-spacer thickness)] x 100

In the comparative example in which the ester value was less than the range of the present invention, the surface irregularities were unclear and the moldability was inferior. On the other hand, in each example, the surface irregularities were clear and the moldability was good.

As described above, the laminated sheet having the uneven pattern on the surface in the present invention has a compressive residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 hours × 50% after compression) of the flexible polyurethane foam as compared with the conventional one. Even if it is small, the uneven pattern can be made clear, and by using the soft polyurethane foam whose compression residual strain is smaller than the conventional one, the uneven pattern can be used even when it is used for a long time as a skin material for a seat. It is possible to suppress the blurring and maintain a good uneven pattern.

10 Laminated sheet with uneven pattern on the surface 11 Soft polyurethane foam 21 Surface member 23 Uneven pattern 24 Convex part 25 Concave

Claims (4)

In a laminated sheet in which a flexible surface member is laminated and integrated with a flexible polyurethane foam and has an uneven pattern formed by heat compression molding on the surface.
The flexible polyurethane foam is
When other polyols are included together with the polyol having an ester group
When containing at least one of a phosphate ester flame retardant or an ester additive together with a polyol having an ester group,
Either that it does not contain a polyol having an ester group and contains at least one of a phosphate ester flame retardant or an ester additive.
The ester value (in accordance with JIS K0070) in these cases is 40 to 400 mgKOH / g.
The surface of the flexible polyurethane foam has irregularities shaped by the heat compression molding.
The surface of the laminated sheet has the uneven pattern due to the unevenness on the surface of the flexible polyurethane foam.
A method for producing a laminated sheet having an uneven pattern on the surface, wherein the height of the convex portion or the depth of the concave portion of the concave-convex pattern formed on the surface of the laminated sheet is 3 to 30 mm. The flexible polyurethane foam was heat-compressed and compressed at 80 ° C. for 240 seconds to 50% of the original thickness using a spacer of 5 mm with respect to the flexible polyurethane foam having a square cross section of 50 mm on a side and a thickness of 10 mm. The method for producing a laminated sheet having an uneven pattern on its surface according to claim 1, wherein it is made of a flexible polyurethane foam having a molding ratio of 70 to 100% calculated by the following formula using the thickness.
Molding rate (%) = [(original thickness-thickness after compression) / (original thickness-thickness of spacer)] x 100 A method for producing a laminated sheet having an uneven pattern on the surface by heat-compressing the surface of the laminated sheet in which a flexible surface member is laminated and integrated with a flexible polyurethane foam by a pressurizing device having an uneven pattern formed on the surface. In
The flexible polyurethane foam is
When other polyols are included together with the polyol having an ester group
When containing at least one of a phosphate ester flame retardant or an ester additive together with a polyol having an ester group,
Either that it does not contain a polyol having an ester group and contains at least one of a phosphate ester flame retardant or an ester additive.
The ester value (in accordance with JIS K0070) in these cases is 40 to 400 mgKOH / g.
The surface member and the flexible polyurethane foam are welded by frame lamination.
The surface of the flexible polyurethane foam has irregularities shaped by the heat compression molding.
The surface of the laminated sheet has the uneven pattern due to the unevenness on the surface of the flexible polyurethane foam.
A method for producing a laminated sheet having an uneven pattern on the surface, wherein the height of the convex portion or the depth of the concave portion of the concave-convex pattern formed on the surface of the laminated sheet is 3 to 30 mm. The flexible polyurethane foam was heat-compressed and compressed at 80 ° C. for 240 seconds to 50% of the original thickness using a spacer of 5 mm with respect to the flexible polyurethane foam having a square cross section of 50 mm on a side and a thickness of 10 mm. The method for producing a laminated sheet having an uneven pattern on its surface according to claim 3, further comprising a flexible polyurethane foam having a molding ratio of 70 to 100% calculated by the following formula using the thickness.
Molding rate (%) = [(original thickness-thickness after compression) / (original thickness-thickness of spacer)] x 100

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