JP6774892B2 - Skin material and integrally foam molded product using it - Google Patents

Description

The present invention relates to a skin material used for a vehicle seat and an integrally foam molded product using the same.

As described in Patent Document 1, for example, the skin material used for a conventional vehicle seat has a three-layer structure consisting of a skin layer, an elastic layer, and a non-woven fabric layer, and the skin material laminated on these three layers is overheated by a press. -A method of manufacturing a headrest by filling the inside with urethane foam after forming a three-layered skin material by applying pressure to form a three-layered skin material is described.

On the other hand, Patent Document 2 describes a sheet trim cover having a two-layer structure in which a skin material and a wading material are laminated, and the surface of the wading material is heated by a burner to be melted and the skin material is laminated to form a two-layer structure. A method of forming a seat trim cover and filling the inside with urethane foam to manufacture a headrest is described.

Further, in Patent Document 3, a plurality of skin pieces in which a polyurethane film is used as a lining material are sewn together on a outer material formed of genuine leather, fabric, synthetic leather, etc., and the sewn portion is laminated with a resin film on a non-woven fabric. The configuration covered with the strip material is described.

Japanese Unexamined Patent Publication No. 2014-171801 Japanese Patent No. 5734698 Japanese Unexamined Patent Publication No. 2014-10833

The skin material described in Patent Document 1 can give a soft feel to the surface of the skin material by sandwiching a wading material in the middle. However, since it has a three-layer structure, there is a problem that the handling of each material and the process of laminating the three layers are troublesome and the manufacturing cost is high.

On the other hand, Patent Document 2 describes a configuration in which the number of parts is reduced and the laminating process is relatively simplified by forming the seat trim cover, which is the skin material of the seat, with the skin material and the wading material. ing. It is also described that a uniform low air permeability layer is formed by heating the surface of the wading material and pressing the molten surface to crush and stretch the wading cell film. However, in the configuration described in Patent Document 2, since the resin film as the barrier layer corresponding to the non-woven fabric of Patent Document 1 is not used, the urethane foam stock solution permeates into the low air permeability layer formed in the wading material and hardens. However, there is a possibility that uneven hardness will occur partially.

Further, even in the configuration described in Patent Document 3, since the resin film as the barrier layer corresponding to the non-woven fabric of Patent Document 1 is not used for the plurality of skin pieces sewn in a bag shape, the urethane foam stock solution is wading. There is a possibility that the low air permeability layer formed on the material will permeate and harden, resulting in partial uneven hardness.

The present invention can solve the above-mentioned problems of the prior art to prevent the urethane foam stock solution from permeating into the skin material, and the surface of the skin material feels soft without using a wading material or a polyurethane film. It is an object of the present invention to provide an epidermis material having a two-layer structure capable of producing the same material, and an integrally foamed molded product using the same.

In order to solve the above-mentioned problems, in the present invention, the epidermis material covering the member formed of the foam material is formed by directly laminating the epidermis portion forming the surface of the epidermis material and the back side of the epidermis portion to foam. It is characterized in that it is provided with a film portion made of a polymer material having minute irregularities formed by transferring to a surface in contact with the material.

Further, in order to solve the above-mentioned problems, in the present invention, the present invention has a two-layer structure of a skin portion and a film portion formed by being supplied in a liquid state to the back surface of the skin portion and directly laminated. An epidermis material that covers a member formed of a material, wherein the film portion is formed of a polymer material and has minute irregularities formed by being transferred to a surface of the film portion in contact with a foam material. Material.

Further, in order to solve the above-mentioned problems, in the present invention, a molded member formed of a foam material and a molded member
It is an integrally foam molded product including a skin member that covers the molded member, and the skin member is laminated directly on the skin portion on the back side of the skin portion that forms the surface of the skin member and the skin portion. The film portion is made of a polymer material, and is characterized by having minute irregularities formed by transferring to a surface of the film portion in contact with the molding member.

According to the present invention, a two-layer structure capable of preventing the permeation of the urethane foam stock solution into the skin material and giving a soft feel to the surface of the skin material without using a wading material or a polyurethane film. It is possible to provide a skin material and an integrally foamed molded product using the same.

It is a block diagram which shows the apparatus structure for forming the skin material which concerns on embodiment of this invention. It is sectional drawing of the skin material which concerns on embodiment of this invention. It is sectional drawing of the mold and the skin member which shows the state which attached the skin member molded for a headrest to the mold, and started to supply urethane foam material to the inside, according to the Example of this invention. It is sectional drawing of the mold and the skin member which shows the state in which the skin member molded for a headrest is attached to the mold, and the urethane foam is filled inside, according to the Example of this invention. It is an example of the integrally foam molded part which concerns on embodiment of this invention, and is sectional drawing of a headrest. It is an example of the integrally foam molded part which concerns on embodiment of this invention, and is the perspective view of the vehicle seat.

In the present invention, the skin material has a two-layer structure in which the skin and the resin film layer are laminated, so that the laminating process is simplified and the resin film layer prevents the urethane foam stock solution from penetrating into the skin. Further, by molding the skin material having such a structure into a bag shape and filling the inside with urethane foam, it is possible to manufacture an integrally foamed molded product such as a head rest and an arm rest without causing a defect in appearance. I made it.

Hereinafter, examples of the present invention will be described with reference to the drawings.

Hereinafter, the method for forming the skin material and the method for integrally foam molding using the skin material in this embodiment will be described.

[Method of forming epidermis material]
The method of forming the skin material in this embodiment will be described with reference to FIG.
In FIG. 1, 110 is an epidermis and 120 is a resin film layer. Reference numeral 131 denotes a resin film material extruder that supplies a raw material (liquid) for the resin film layer 120. Reference numeral 132 denotes a cooling roller that cools the resin film material 121 supplied on the skin 110 and forms the resin film layer 120 so that the thickness becomes uniform. Reference numeral 133 denotes a corona discharge generator, which generates a corona discharge in the vicinity of the surface of the resin film layer 120 formed on the skin 110, thereby modifying the surface of the resin film layer 120 to facilitate adsorption. Reference numeral 140 denotes a supply roller for supplying the skin 110, and reference numeral 150 denotes a winding roller for winding the skin 110 having the resin film layer 120 formed on the surface thereof.

The transport means (not shown) that transports the resin film material extruder 131, the cooling roller 132, the corona discharge generator 133, the supply roller 140, the take-up roller 150, and the skin 110 in the direction of the arrow is controlled by the control unit 160. ..

The reason why the surface of the resin film layer 120 is modified by corona discharge to facilitate adsorption is when the urethane foam stock solution is injected into the bag-shaped skin material and foamed inside in a later step. This is to improve the adhesion between the resin film layer 120 and the urethane foam.

In the configuration shown in FIG. 1, the skin 110 is supplied from the supply roller 140, is conveyed by the conveying means at a constant speed in the direction of the arrow, and is taken up by the take-up roller 150 and collected. Further, in the configuration shown in FIG. 1, the skin 110 has a certain width in the direction perpendicular to the paper surface, and the cooling roller 132 and the corona discharge generator 133 also have a depth corresponding to the width of the skin 110. ing.

The epidermis 110 is made of cloth or leather or artificial leather. As the cloth, any one of tricot, jersey, woven fabric, non-woven fabric, etc., or a similar one is used.

The resin film layer 120 is made of a polymer material such as polyethylene, polypropylene, or polyurethane as a raw material.

The procedure for forming the skin material 100 by laminating the skin 110 and the resin film layer 120 with the configuration shown in FIG. 1 will be described.

First, the skin 110 supplied from the supply roller 140 is conveyed at a constant speed in the direction of the arrow in FIG. 1 by the conveying means. In this state, the resin film material extruder 131 is controlled by the control unit 160, and the resin film material 121 continuously supplies a constant amount onto the skin 110 in synchronization with the transportation of the skin 110 by the transport means. To do. The resin film material extruder 131 is provided with a heating means (not shown) to heat the resin film material 121 and store it in a liquid state. From the resin film material extruder 131, the resin film material 121 is supplied onto the epidermis 110 in a liquid state.

Next, the resin film material 121 supplied in liquid form on the skin 110 is thinned over the entire width of the surface of the skin 110 by a cooling roller 132 controlled by the control unit 160 and rotating in synchronization with the conveying means. The resin film layer 120 is formed by being uniformly spread and cooled. The thickness of the resin film layer 120 formed on the skin 110 can be adjusted by the distance between the transport surface for transporting the skin 110 and the cooling roller 132.

The skin 110 on which the resin film layer 120 is formed by being cooled by the cooling roller 132 is continuously conveyed by the conveying means and passes under the corona discharge generator 133. The corona discharge generator 133 is installed so as to maintain a narrow distance from the resin film layer 120 formed on the skin 110. The corona discharge generator 133 is controlled by the control unit 160 to generate a corona discharge in synchronization with the conveying means. By this corona discharge, the surface 122 of the resin film layer 120 formed of the polymer material passing directly underneath is modified to be easily adsorbed, and the adhesiveness with the foam material can be improved.

The skin material 100 formed by laminating a resin film layer 120 having a surface 122 modified on the skin 110 to facilitate adsorption has a cross-sectional shape as shown in an enlarged view in FIG. The skin material 100 is controlled by the control unit 160, wound up by a winding roller 150 that rotates in synchronization with the conveying means, and collected.

As described above, in this embodiment, the resin film material 121 supplied in liquid form is used as the skin without using the wading material (slab foam layer) supplied in sheet form as described in Patent Documents 1 and 2. By directly supplying the resin film layer 120 to the 110 to form the resin film layer 120, the manufacturing process can be simplified, and both the equipment cost and the material cost can be reduced.

Further, as described in Patent Document 2, when the skin material is formed only by the skin and the wading material (slab foam layer) without using the resin film, the skin material and the wading material are supplied in the form of sheets, respectively. Then, it was necessary to heat and melt both sides of the wading material with a burner, attach the skin material to one side, and process the other side so as to have low air permeability, which was complicated in the process.

On the other hand, according to the present embodiment, since the melted liquid resin film material 121 is directly supplied on the skin 110, the steps of heating and melting with a burner and the step of supplying the sheet-shaped wading material are unnecessary. Therefore, the configuration of the equipment can be simplified and the number of processes can be reduced.

Further, in the case of the conventional three-layer structure or two-layer structure, the configuration of the equipment for laminating the three layers is complicated in order to supply the members constituting each layer as a sheet-like member. On the other hand, in the case of the two-layer structure skin material 100 described in this embodiment, only the skin 110 is supplied as a sheet-like member, and the material of the resin film layer 120 is the surface of the skin 110. Can be supplied in liquid form. Thereby, according to this embodiment, the configuration of the equipment for laminating in the two-layer structure can be relatively simplified.

In the example shown in FIG. 1, a method of improving the adhesiveness with a foam material by modifying the surface 122 of the resin film layer 120 by generating a discharge with a corona discharge generator 133 to facilitate adsorption. As described above, instead of the corona discharge generator, a heating roller having fine irregularities formed on the surface is pressed against the surface of the resin film layer 120 to form minute irregularities on the surface 122 of the resin film layer 120, resulting in foaming. The adhesiveness with the material may be improved.

Further, instead of the above-mentioned corona discharge generator 133, fine irregularities may be formed on the surface of the cooling roller 132 to form fine irregularities on the surface 122 of the resin film layer 120. That is, when the resin film material 121 supplied from the resin film material extruder 131 onto the skin 110 is cooled by the cooling roller 132 and molded so that the thickness of the resin film layer 120 becomes uniform, the cooling roller 132 The minute irregularities formed on the surface may be transferred to the surface of the resin film layer 120 to form the minute irregularities on the surface 122 of the resin film layer 120 to improve the adhesiveness with the foam material.

Further, instead of the above-mentioned corona discharge generator 133, sandblasting or ozone treatment is performed to form minute irregularities on the surface 122 of the resin film layer 120 to improve the adhesiveness with the foam material. Is also good.
In the embodiment shown in FIG. 1, the material of the resin film layer 120 was supplied in liquid form by a film material extruder, but instead, a sheet-shaped resin film sheet was supplied to the skin using a supply roller or the like. It may be supplied to the surface of 110.

[Manufacturing method of integrally foam molded product]
As an example of the integrally foam molded product using the skin material 100 described above, an example of manufacturing a headrest of a passenger car will be described.

The skin material 100 described above is cut and sewn to form a bag-shaped skin member 300 for a headrest, and a cover 305 formed of the mesh-shaped member is attached. With the stay 340 mounted inside the skin member 300, a nozzle 321 for injecting a foam material is inserted into the skin member 300 formed in a bag shape from the vicinity of an opening (not shown) of the skin member 300.

Next, as shown in FIG. 3, the stay 340 is attached, and the skin member 300 into which the nozzle 321 is inserted is sandwiched between the molds 311 and 312, and is formed in a bag shape from a urethane foam stock solution supply portion (not shown). The urethane foam stock solution 331 is supplied to the inside of the skin member 300. Here, the tip portion of the nozzle 321 is covered with a cover 305 formed of a mesh-like member. In FIG. 3, for the sake of simplicity, the description of the detailed configuration of the opening formed in the skin member 300 and the surrounding portion of the skin member 300 is omitted.

The urethane foam stock solution 331 ejected from the nozzle 321 into the skin member 300 formed in a bag shape reaches the skin member in a state where the momentum is weakened by hitting the cover 305. In this state, since the resin film layer 120 is formed on the inner surface of the skin member 300 (the surface in contact with the urethane foam stock solution 331), the urethane foam stock solution 331 does not soak into the skin 110.

The urethane foam stock solution 331 supplied from the nozzle 321 to the inside of the skin member 300 foams inside the skin member 300 to form the urethane foam 330, and as shown in FIG. 4, the skin member 300 is formed into molds 311 and 312. It is pressed against and molded into the shape of a headrest.

In this state, the surface 122 of the resin film layer 120 is modified by the corona discharge to be easily adsorbed, and the adhesiveness of the urethane foam 330 is improved. Therefore, the urethane foam 330 is in close contact with the skin member 300. It has become. By using such a skin member 300, the urethane foam stock solution 331 does not soak into the skin 110.

FIG. 5 shows a state in which the molded headrest 350 is taken out from the molds 311 and 312. As shown in FIG. 2, the surface of the skin member 300 in contact with the urethane foam 330 is the surface 122 of which the resin film layer 120 has been modified, so that the urethane foam 330 and the skin member 300 are in close contact with each other. It is in a state of being.

By using such an epidermis member 300, the urethane foam stock solution 331 does not soak into the epidermis 110, so that the epidermis 110 is partially cured or foamed to the outside through a gap of a stitched portion (not shown) of the epidermis 110. It is possible to eliminate the possibility that urethane leaks out and spoils the appearance of the headrest 350.

According to this embodiment, the material cost of the headrest and the material cost of the headrest are increased by directly forming the resin film layer 120 on the skin 110 without using the wading material (slab foam layer) as described in Patent Documents 1 and 2. The processing cost can be reduced.

Further, in the case of the conventional three-layer structure or two-layer structure, in order to supply the members constituting each layer as sheet-like members, the configuration of the manufacturing equipment required for the handling is relatively complicated. According to this embodiment, it is possible to relatively simplify the configuration of equipment for supplying a liquid material to the skin member supplied in the form of a sheet and laminating it in a two-layer structure.

In the examples described above, the case of forming the headrest as an example of the integrally foam molded product has been described, but the present invention can also be applied to other parts formed by integrally foam molding. For example, as shown in FIG. 6, in the vehicle seat 600, in addition to the headrest 603 (corresponding to 350 in FIG. 5) described above, the seat cushion 601 or the seat back 602 formed by integral foam molding, integrally foam molding. It can also be applied to the armrest 604 formed by.

Further, even if it is not a passenger car, it can be applied to a portion formed by integral foam molding of a chair.

Although the present invention has been specifically described above based on the examples, it is needless to say that the present invention is not limited to the above-mentioned examples and can be variously modified without departing from the gist thereof. For example, the above-described embodiment has been described in detail in order to explain the present invention in an easy-to-understand manner, and is not necessarily limited to those having all the described configurations.

100 ... Skin material 110 ... Skin 120 ... Resin film layer 131 ... Resin film material extruder 132 ... Cooling roller 133 ... Corona discharge generator 140 ... Supply roller 150 ...・ Winding roller 300 ・ ・ ・ Skin member 311, 312 ・ ・ ・ Mold 321 ・ ・ ・ Nozzle 340 ・ ・ ・ Stay 350 ・ ・ ・ Headrest.

Claims (12)

An epidermis material that covers a member made of a foam material.
The epidermis portion forming the surface of the epidermis material and
A skin material comprising a film portion made of a polymer material having minute irregularities formed by being directly laminated on the back side of the skin portion and transferred to a surface in contact with the foam material. The skin material according to claim 1, further comprising a film portion that is supplied in liquid form and directly laminated on the back surface of the skin portion. The minute unevenness formed by the transfer to the surface of the film portion in contact with the foam material of the skin material according to claim 1 is the minute unevenness formed on the surface of the roller pressed against the film portion. An epidermis material characterized in that the unevenness is formed by being transferred to the film portion . The skin material according to claim 1, wherein the skin portion is formed of a cloth. The skin material according to claim 1, wherein the film portion is made of polyethylene, polypropylene, or polyurethane. A skin material having a two-layer structure of a skin part and a film part formed by being directly laminated and supplied to the back surface of the skin part, and covering a member made of a foam material.
The epidermis material is characterized in that the film portion is formed of a polymer material and has minute irregularities formed by being transferred to a surface of the film portion in contact with the foam material. The skin material according to claim 6, wherein the skin portion is formed of a cloth. The skin material according to claim 6, wherein the film portion is made of polyethylene, polypropylene, or polyurethane. Molded members made of foam material and
An integrally foam molded product including a skin member that covers the molded member.
The skin member is
The epidermis portion forming the surface of the epidermis member and
It is provided with a film portion formed by directly laminating the epidermis portion on the back side of the epidermis portion.
An integrally foam molded product characterized in that the film portion is formed of a polymer material and has minute irregularities formed by transferring to the surface of the film portion in contact with the molding member. The integrally foamed molded product according to claim 9, wherein the molded member is a member of a headrest of a passenger car. The integrally foam molded product according to claim 9, wherein the molded member is a member of an armrest of a passenger car. The integrally foam molded product according to claim 9, wherein the molded member is a member of a seat cushion or a seat back of a passenger car.

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